DOCU Bottling Plant en

Application description 10/2015
Simulation with SIMIT Simulation

Framework and PCS 7 in a practical
example
SIMIT Simulation Framework V8.1, SIMATIC PCS 7 V8.1
https://support.industry.siemens.com/cs/ww/de/view/77362399
Warranty and liability
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Simulation with SIMIT and PCS 7 in a practical example

Entry ID: 77362399, V1.0, 10/2015 2
Preface
Preface
Aim of this Application Example
The aim of this application example is to introduce additional functions and libraries
in a practical example, in addition to the SIMIT Simulation Framework Getting
Started. The associated example project includes a complete simulation from the
signals to the process.
Key Content
The following main topics are covered in this application example:
The structure of a simulation project from the signal level to the process level
(partly with reference to existing documentation)
Customizing templates
The structure of the process level with the FLOWNET library
The simulation of a conveyor system with components of the CONTEC library
Automatic generation of the device level using the simulated conveyor system
Pre-prepared scripts which can be used for operator training, for example.
Validity
SIMIT Simulation Framework V8.1
SIMATIC PCS 7 V8.1 SP1

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Table of contents
Table of contents
Warranty and liability................................................................................................... 2
Preface .......................................................................................................................... 3
1 Task Description and Solution ......................................................................... 6
1.1 Task ...................................................................................................... 6
1.2 Solution................................................................................................. 6
1.2.1 Overview of the complete solution ....................................................... 7
1.2.2 Core Functionality ................................................................................ 8
1.2.3 Hardware and Software Components .................................................. 8
2 Initial Work on the Project .............................................................................. 10
2.1 Presentation of the Project ................................................................. 10
2.2 Configuring the PLCSIM Interface in the SIMATIC Manager ............. 10
2.3 Configuring the PLCSIM Interface in SIMIT ....................................... 11
2.4 Verifying Communication between PLCSIM and SIMIT .................... 12
2.5 The Current Status of your Project ..................................................... 12
3 Creating the Device Level ............................................................................... 14
3.1 Creating a Template ........................................................................... 14
3.2 CMT Import ........................................................................................ 18
3.3 Generating the Device Level .............................................................. 21
3.3.1 Adapting the Template ....................................................................... 21
Conveyor System Simulation Chart ................................................................... 24

3.3.2 Procedure for “Generating the Device Level”..................................... 26
3.3.3 Final Adjustments/Additions ............................................................... 27
4 Modeling Physical Correlations ..................................................................... 30
4.1 Establishing the Physical Process Model........................................... 30
4.2 Model Plant Section “Plant1” .............................................................. 30
4.2.1 Creating Macros ................................................................................. 30
4.2.2 Additional Preparations ...................................................................... 34
4.2.3 Creating the Chart “RMT1” ................................................................. 34
4.3 Model Plant Section “Plant2” .............................................................. 44
4.3.1 Preparation ......................................................................................... 44
4.3.2 Creating the Chart “Reactor1” ............................................................ 44
4.3.3 Creating the Chart “Reactor2” ............................................................ 47
5 Simulation of the Conveyor System .............................................................. 53
5.1 Modeling the Goods Conveyed .......................................................... 53
5.1.1 Creating the List of Goods Conveyed ................................................ 53
5.1.2 Calculating the Color of the Goods Conveyed ................................... 54
5.1.3 “Calc” Chart ........................................................................................ 55
6 Animation of the Crown Cap Machine ........................................................... 58
6.1 Creating the 3D Viewer Control ......................................................... 58
6.2 Creating the Animation ....................................................................... 59

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Table of contents
7 Scripts and Snapshots .................................................................................... 62

7.1 Scripts................................................................................................. 62
7.2 Snapshots .......................................................................................... 63
8 Commissioning ................................................................................................ 64
9 Related literature ............................................................................................. 65
10 History............................................................................................................... 65

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1 Task Description and Solution
1.1 Task

1.1 Task
PCS 7 projects are becoming more and more complex due to the increasingly
significant demand for availability and individuality of systems. In this regard,
the automation programs must also undergo extensive testing.
To make this possible, certain system states and feedback are required from
actuators and sensors to test whether the automation program is functioning
correctly.
The provision of feedback or the system state is very laborious or not possible
without a suitable tool. For this reason, nowadays one can find tools such as
SIMIT Simulation Framework (hereafter referred to as SIMIT), which simplify the
simulation of signals, devices and process states in a significant way.
1.2 Solution
This application example given here describes how to use the SIMIT simulation
software to easily and quickly create the required simulation for a unit for the
manufacture and packaging of soft drinks. The plant sections raw material tanks,
reactors and a bottling plant are used for the simulation.
The basis for the simulation project described here is the PCS 7 project "bottling
plant", which you can find on the same article page.

The application example provides a template which includes the simulation of
important physical processes, devices, and signals of a raw material tank, stirred
tank reactor and the filling unit. The installation is modular and is based on physical
principles.
Its utilization offers the following advantages:
A reduction of the knowledge necessary to develop simulations
A decrease in the configuration effort
Flexible installation and adjustment
Standardized structures

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1.2 Solution
1.2.1 Overview of the complete solution
Diagram
The following figure shows parts of a possible style depth of a simulation solution
of a filling unit.
Figure 1–1
Description
The application example "virtual commissioning with SIMIT Simulation Framework
for typical process and production automation" includes a PCS 7 project from
a beverage blending and bottling plant and the associated simulation model.
The PCS 7 project does not form part of the description given here and serves
solely as a basis for the description of the simulation model.
The simulation model is divided into three levels:
Signal level
Device level
Process level
You can find a description of the levels and of SIMIT in the application example
"SIMIT Getting Started" in chapter 1 "SIMIT at a glance" (\3\).

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1.2 Solution
Aim
The aim of the application example given here is to introduce functions and
libraries which are not described in Getting Started. In this example, the following
topics will be highlighted in particular:
FLOWNET library
CONTEC library
The function "Generating the device level"
Script function
Creating/optimizing templates
Delimitation
Physically speaking, the technical process is illustrated in a simplified way by
assuming ideal conditions.
Required Knowledge
Fundamental knowledge of the following specialist fields is a prerequisite:
Basic knowledge of process technology
Basic knowledge of physical modeling
Engineering with SIMATIC PCS 7 and Advanced Process Library (APL)
Knowledge of control technology
1.2.2 Core Functionality
The individual components of the PCS 7 project "Bottling Plant" simulation are
described in the following section. The simulation consists of three main
components:
Raw material tanks
Reactors
Filling
The main components with the associated technical functions are derived from
the technological hierarchy of the PCS 7 project.
You can find information on the generation procedure and the individual
components such as signals, devices and processes in the application example
"Simulation of a PCS 7 stirred tank reactor with SIMIT simulation framework"
chapter 1.2. "Solution" (\4\).
1.2.3 Hardware and Software Components
The application example has been created with the following components:
Hardware Components
Table 1–1
Component Instructions
SIMATIC PCS 7 ES/OS IPC847D W7 For the PCS 7 V8.1 example project
and the SIMIT V8.1 example project

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1.2 Solution
Note In case of different hardware, please take heed of the suggested hardware
configuration for installing the software components.
The suggested hardware configuration can be found in the read me file of the
PCS 7 (online) \5\.
Software Components
Table 1–2
Component Instructions
SIMATIC PCS 7 V8.1 SP1 Part of SIMATIC PCS 7 ES/OS IPC847D
W7
S7-PLCSIM The license is not a part of SIMATIC PCS 7
ES/OS IPC847D
SIMIT ULTIMATE V8.1 The software and license are not a part of
SIMATIC PCS 7 IPC847D
Note SIMIT V8.1 is offered in three versions: "STANDARD", "PROFESSIONAL" and

"ULTIMATE". An overview of the contained modules is available in chapter 1.2
"product versions" of the manual "SIMIT (V8.1) Operating Manual" (\6\). In the
application example, the modules "PLCSIM coupling" and "CMT import (CMT -
control module type)", Component Type Editor (CTE) as well as the libraries
FLOWNET and CONTEC are used. These do not form part of SIMIT V8.1
STANDARD.
Example Files and Projects

The following table contains all the files and projects used in this application
example.
Table 1–3
File/project Note
77362399_PROJECT_BottlingPlant_SIMIT_V81.zip SIMIT V8.1 example project
77362399_PROJECT_BottlingPlant_PCS7_V81.zip PCS 7 V8.1 example project
77362399_DOCU_Bottling_Plant_en.pdf This document

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2 Initial Work on the Project
2.1 Presentation of the Project

The following will demonstrate how to create the simulation project. The functions
and approaches which are already described in other application examples will
simply be named. The corresponding description will be referenced.
2.1 Presentation of the Project

Description of the Plant
The basic liquid materials are dispensed from three raw material tanks into two
reactors. The flow rates are regulated by valves. The liquids are then heated or
cooled in the reactors. Then the liquids are bottled. After the filling process, the
bottles are taken away on conveyor belts.
Task Description for the PCS 7 Project "Bottling Plant"

The bottling plant is depicted in SIMIT:
Generating the signal level and coupling with PLCSIM
Generating the device level and the simulation of the conveyor belt
While doing this you will get to know the function "Generating the device level".
Generating the physical models
When generating the physical models you will get to know the FLOWNET
libraries.
Generating the scripts which can be used for operator training sessions,
for example.
2.2 Configuring the PLCSIM Interface in the SIMATIC

Manager
Before you start configuring SIMIT, you must first retrieve the "BottlingPlant_MP"
project in the SIMATIC Manager, change the settings and load PLCSIM.
The approach is described in the application example SIMIT Getting Started (\3\)
in chapter 2.2 "Configuring the PLCSIM interface in the SIMATIC Manager.
Note The "BottlingPlant_MP" project includes two automation systems.

For this reason, steps 4 to 9 should be executed twice (once per AS).

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2.3 Configuring the PLCSIM Interface in SIMIT
2.3 Configuring the PLCSIM Interface in SIMIT

The configuration approach is described in the application example SIMIT Getting
Started (\3\) in chapter 2.3 "Configuring the PLCSIM interface in the SIMATIC
Manager.
Note The "BottlingPlant_MP" project includes two automation systems. For this
reason, steps 1 to 4 in table 2-3 and steps 1-8 in table 2-4 should be executed
twice (once per AS).
As two PLCSIM couplings are created in the application example, the couplings
should be assigned unique names and one time slice each. The couplings have
the following names in the application example:
Coupling to AS1 "1_SignalLevel_PLCSIM_AS1"
Coupling to AS1 "2_SignalLevel_PLCSIM_AS2"
Assigning the Time Slice

You can set the cycle times of the time slices in the properties window of the
project manager. Time slices 2 and 3 are used in the application example.
A cycle time of 50 ms is set for each time slice.
Figure 2–1

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2.4 Verifying Communication between PLCSIM and SIMIT
You can assign the relevant time slice in the properties window of the coupling.
You can enter the number of the PLCSIM instance in the field "PLCSIM number".
You will find the number in the header of the PLCSIM window for each AS. The
PLCSIM number 1 is also assigned to the coupling for AS1 in the following image.
Figure 2–2
Set the time slice 3 and the PLCSIM number 2 for AS2.
2.4 Verifying Communication between PLCSIM and SIMIT

In order to prevent communication errors between PLCSIM and SIMIT, you can
test the connection in a simple way.
The precise approach is described in the application example SIMIT Getting
Started (\3\) in chapter 2.4 "Verifying communication between PLCSIM and SIMIT".
2.5 The Current Status of your Project

In preparation for the actual creation of the process simulation for the "Bottling
Plant" project, you have completed the following tasks:
You have retrieved the PCS 7 project "Bottling Plant" and downloaded the
configured hardware in the virtual AS (PLCSIM).
You have created two PLCSIM couplings in SIMIT and imported the symbol
tables you had previously exported from PCS 7 into SIMIT.
You have set the cycle times for the time slices and assigned a time slice to
each coupling.
You have assigned the PLCSIM number to each coupling.
You have tested the communication between PLCSIM and SIMIT.
At the current state of your project you are now able to perform signal tests. At this
stage of the simulation, you can see whether the signals are communicated from
the control to the signal level (see Figure 2–3).
Tests such as the opening and closing of valves can be validated at this stage.

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You are still unable to simulate the time response or the transient response of
processes. This requires you to describe the process in detail and simulate it in
SIMIT. The following chapters describe a possible process simulation for the
"Bottling Plant" project.
Figure 2–3

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3 Creating the Device Level
3.1 Creating a Template

In the previous chapter, the PLCSIM couplings were configured. The PLCSIM data
can be accessed for writing and reading.
If the AS sends control signals, these are sent in real application to actuators.
These then perform an action that changes the process in some way. This could
be, for example, a level increase or the sinking of a mass flow. This change must
be detected by sensors and sent back to the AS.
In this chapter, the actuators and sensors are replicated. While doing this, you will
get to know and use the functions “CMT import” and “Generation of a device level”.

To be able to use the “CMT import” and “Generation of a device level” functions
effectively, you must create corresponding templates for the actuators and sensors
used. The templates must match the CMTs in PCS 7. That means that the
template name is identical to the CMT name.
The following list comprises the required templates.
AMON_Std
BottlingAnalogVlv
Bottling_2WayValve
Bottling_Dose
Bottling_MotorLean
Bottling_MotorRev
Bottling_MotorSimoCode
Bottling_MotorSinamics
Bottling_PID
Bottling_ValveLean
Conv
There are two options for creating templates. The first option is to adapt the
existing templates (base templates). The second option is to create a new one.
In order to adapt the base templates, they have to be copied. For example, they
could be copied into the folder project templates. After that it is possible to open
and edit them.
Procedure
The following section will provide you with some examples of how to create or
adapt templates.
AMON_Std:
First of all, the interfaces to the CMT must be defined before creating a template.
To do this, the following tasks must be performed in the SIMATIC Manager:
1. Open the CMT “AMON_Std” in the master data library of the “BottlingPlant”
project.
2. Open the technical connections of the CMT “View > Technical connections”.
3. Take note of the names of the assigned blocks and the names of the
associated signals and parameters which you need in the SIMIT template.

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The following figure outlines these for the “AMON_Std”.
Figure 3–1
The template “AMON_Std” is created from the base template “AnalogMonitoring”

from the folder “PCS 7 AP Library V80”. The following tasks need to be performed:
4. Open the base template folder “PCS 7 AP Library V80” in the Task-Card
“templates” in the Tools window.
5. Select the template “AnalogMonitoring”.
6. Drag the template and drop it into the project templates.
Figure 3–2
7. Change the name to “AMON_Std".

8. Double-click to open the template.
9. Make the changes according to the following table.

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Table 3–1
Component Property Old value New value
Connector Name {$ChartName}/X {$ChartName}/PV
Phys2Raw Name Phys2Raw#1 {$ChartName}_Phys2Raw
Phys_Lower_ PV_LR_Value PV\Scale\Low
Limit
Phys_Upper_ PV_HR_Value PV\Scale\High
Limit
Signed2Unsigned Name Signed2Unsigned {$ChartName}_Signed2Unsig
#1 ned
Input Signal COUPLING COUPLING PV\PV_In
PV_SymbolName
10. Insert text boxes to improve clarity according to the following figure.
Figure 3–3
11. Save and close the template.
Bottling_2WayValve:
Before creating the template, the names of the assigned blocks and the associated
signals and parameters which you want to address in the SIMIT template need to
be compiled (see steps 1 to 4 AMON_Std). The following table compiles these:
Table 3–2
Block Signal / parameter
CtrlV0 PV_Out
CtrlV1 PV_Out
CtrlV2 PV_Out
FbkP0 PV_In
FbkV0 PV_In
FbkV1 PV_In
FbkV2 PV_In

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Block Signal / parameter

V MonTiV0Dynamic
V MonTiV1Dynamic
V MonTiV2Dynamic
The template can be created with this information. The following figure shows
the arrangement and the interconnection of the necessary components.
Figure 3–4
The following list comprises the properties of the components.
Table 3–3
Component Property Value
Output Signal COUPLING Ctrl0\PV_Out
MUL Name {$ChartName}_MUL_V0
X1 V\MonTiV0Dynamic
X1 V\MonTiV1Dynamic
X1 V\MonTiV2Dynamic
DriveV1 Name {$ChartName}_V0

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3.2 CMT Import

AND Name {$ChartName}_AND
Connector Name {$ChartName}_V0/Hi
Connector Name {$ChartName}_V0/Lo
Connector Name {$ChartName}_V0/Y
Input Signal COUPLING FbkV0/PV_In
Input Signal COUPLING FbkP0/PV_In
Create the remaining templates according to the procedure described above.

Note It is a huge advantage if you give every component which you place on a chart
a unique name. By using {$ChartName} this can be easy and convenient when
using templates. When generating charts, {$ChartName) is replaced by the plan
name. If you place additional components on charts, give each of them a unique
name. This makes it easier to interconnect the components beyond the limits of
the chart at a later date.
3.2 CMT Import

With the aid of templates, you can create the device level with the function “CMT
Import”.
Requirements
To use the function "CMT Import" for automatic model creation, a corresponding
XML file is required, exported from the PCS 7 project. The PCS 7 project must also
be created with the help of CMTs (control module types).
Preparation
Create the following subfolders in the folder "Chart".
1_SignalLevel
2_DeviceLevel
3_ProcessLevel
Procedure
The application example “SIMIT Getting Started” in chapters 3.3.1 “Export of XML
files from PCS 7” and chapter 3.3.3 “CMT Import” describe in detail how to export
the required XML files and carry out the CMT import.

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3.2 CMT Import
The CMT import for the application example given here is described step by step
in the following section.
1. Right-click the “DeviceLevel" folder.
2. Select “Automatic model generation > CMT Import” in the context menu.
3. In the “Coupling” box, select the coupling “1_SignalLevel_PLCSIM_AS1”.
4. Untick the box “Plant3” in the preview.
Figure 3–5
5. Click "Import" to start the import.

6. Click “OK” in the window “Import complete”.

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3.2 CMT Import
7. Execute steps 1 to 6 for the coupling “2_SignalLevel_PLCSIM_AS2”. Apply

your settings as shown in the following figure.
Note Only the charts for the fill level measuring points are created. The charts for
the conveyor line drives are created with the aid of the function “Generation of
device level”.
Figure 3–6
Result
The device level is created in its entirety for the plant sections “Plant1” and “Plant2”
For the plant section “Plant3”, only the fill level measuring points “LI311” and
“LI312” were created.

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3.3 Generating the Device Level

An additional option for creating a model automatically is the function “Generating
the Device Level”. When using this function, the device level is created using
information from the conveyor system model which is constructed using CONTEC
library components.
Templates are required for this, as with the CMT import. The templates for the
“Generation of the device level” are created in the same way as the templates
for the CMT import.
In the application example given here, the CMT import template
“Bottling_MotorRev” is adapted and saved under the name “Conv”. Then the
conveyor system is replicated using the “Conveyor” components in the CONTEC
library.
3.3.1 Adapting the Template
The following procedure describes how to adapt the template “Bottling_MotorRev”.

8. Create a new template.
9. Name it “Conv".
10. Open the template “Bottling_MotorRev”, select all the components contained in
the template and copy them.
11. Close the template “Bottling_MotorRev” and switch to the template “Conv.”
12. Insert the copied components into the template “Conv”.
13. Adapt the available components as described in the table below:
Table 3-4
Text Text {$ChartName}_MotorRev {$NAME}_MotorRev
Output Signal COUPLING Fwd\PV_Out COUPLING DO_{$NAME}_Fwd
Output Signal COUPLING REv\PV_Out COUPLING DO_{$NAME}_Rev
OR Name OR#1 OR_{$NAME}
MUL Name MUL#1 MUL_{$Name}
Input X1 U\MonTiDynamic 3
Input X2 1.0 0.5
DriveP1 Name DriveP1#1 {$NAME}_U
Connector Name Connector#1 {$NAME}/Run
Connector Name Connector#2 {$NAME}/Dir
Connector Name Connector#3 {$NAME}/Y
NOTc Name NOTc#1 NOTc_{$NAME}
AND Name AND#1 AND_Fwd_{$NAME}
AND Name AND#2 AND_Rev_{$NAME}
Pushbutton Name Pushbutton#1 Pushbutton_{$NAME}_Startlocal
Pushbutton Name Pushbutton#2 Pushbutton_{$NAME}_Stoplocal
Switch Name Switch#1 Switch_{$NAME}_Maint
Switch Name Switch#2 Switch_{$NAME}_Trip

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Input Signal COUPLING COUPLING
FbkFwd\PV_In DI_{$NAME}_FbkFwd
FbkRev\PV_In DI_{$NAME}_FbkRev
StartLocal\PV_In DI_{$NAME}_StartLocal
StopLocal\PV_In DI_{$NAME}_StopLocal
Input Signal COUPLING Maint\PV_In COUPLING DI_{$NAME}_Maint
Input Signal COUPLING Trip\PV_In COUPLING DI_{$NAME}_Trip
14. Insert the components which are additionally required into the template,
as shown in the following figure. These are essential for the sensors of
the components in the conveyor system.
Figure 3–7
15. Adjust the properties of the components as summarized in the table below.
Table 3–5
BConnector Name BConnector_{$NAME}-
SensorA1
Input {$NAME} SensorA1
SensorA2

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SensorA3
SensorA4
Binary Display Name Binary
display_{$NAME}_SensorA1
Input Signal COUPLING
DI_{$NAME}_SA1
DI_{$NAME}_SA2
DI_{$NAME}_SA3

DI_{$NAME}_SA4
SensorB1
Input {$NAME} SensorB1
SensorB2
SensorB3
SensorB4
display_{$NAME}_SensorB1
DI_{$NAME}_SB1
DI_{$NAME}_SB2

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DI_{$NAME}_SB3
DI_{$NAME}_SB4
AConnector Name {$NAME}-Speed
16. Save and close the template “Conv”.
Conveyor System Simulation Chart
In the application example given here, there is a separate chart for the simulation
of the conveyor system. The following will describe how to create this chart.
Chart Properties
1. Create the folder “Conveyor” in the folder “3_ProcessLevel”.
2. Create a new chart “Conveyor_sim” in this folder.
3. Adapt the size and scale in line with the following figure.
Note The dimensions of the components from the CONTEC library play a decisive role
in the simulation as the lengths of the conveyor lines and the sensor positions
are derived from these. You can find more information in chapter 7.3.2.5 “Scale”
in the manual “SIMIT (V8.1)” (\6\).
Figure 3–8
Conveyor System
The conveyor system is created using components from the CONTEC library.
The following section will describe how to create the simulation of the conveyor
system.
1. Place the components “Conveyor-S4”, “ConveyorCurve45-R60” and
“SpurConveyor-2” on the chart “Conveyor_sim”, as shown in the following
figure.

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2. Adjust the properties of the components using the table below.
Figure 3–9
ConvCurvCola Conv5
Conv4
Conv1 Conv2
Conv3
ConvSpur
Conv6
ConvCurvOLimo Conv7
Table 3–6

Conv1 Name Conv1
SensorPositionA1 1200
MatarialType CBoxDS256
TEMPLATE Conv
HIERARCHY Conveyor
Conv2 Name Conv2
Width 12000
NominalSpeed 0.5
NbrOfSensorsA 3
ConvSpur TEMPLATE Conv
HIERARCHY Conveyor
Conv3 Name Conv3
Width 7200
RemoveA3 Conv3-SensorA3 OUT
NbrOfSensorsA 3
TEMPLATE Conv
HIERARCHY Conveyor

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Conv4 Name Conv4
TEMPLATE Conv
HIERARCHY Conveyor
Conv6 Name Conv6
TEMPLATE Conv
HIERARCHY Conveyor
ConvCurvCola Name ConvCurvCola
TEMPLATE Conv
HIERARCHY Conveyor
ConvCurvOLimo Name ConvCurvOLimo
TEMPLATE Conv
HIERARCHY Conveyor
Conv5 Name Conv5
Width 5000
NbrOfSensorsA 3
SensorPositionA3 10
TEMPLATE Conv
HIERARCHY Conveyor
Conv7 Name Conv7
Width 5000
NbrOfSensorsA 2
TEMPLATE Conv
HIERARCHY Conveyor
3.3.2 Procedure for “Generating the Device Level”
The following section will describe the procedure for the function “Generating the
Device Level”.
Requirement
The requirement for using the function “Generating the Device Level” is that you
have created the relevant template (if you are not using the base templates) and
you have created the model of the conveyor system with the components from the
CONTEC library.

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Procedure
1. Right-click “Plant3” in the “DeviceLevel" folder.
2. Select “Automatic model generation > Device Level Generation” in the context
menu.
3. Set the coupling “2_SignalLevel_PLCSIM_AS2” in the “Coupling” box.
Figure 3–10
4. Click "Import".
5. Click “OK” in the window “Import complete”.
3.3.3 Final Adjustments/Additions
Adjustments and/or additions have to be made to the charts “ConvSpur” and

“ConvCurvCola” because the template used does not meet all requirements.
Note If you have several charts of the same type which need to be adapted after
generating the device level, it is sensible to have a separate template for these
charts.

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ConvSpur
1. Open the chart ConvSpur.
2. Insert two components from each of the types “Output” and “BConnector”.
3. Interconnect these as shown in the following figure.
Figure 3–11
Adjust the properties of the components as summarized in the table below.
Table 3–7
Output Signal 2_SignalLevel_PLCSIM_AS2
DO_ConvSpure_S_AB
DO_ConvSpure_S_AD
BConnector Name ConvSpur-Switch1
BConnector Name ConvSpur-Switch2
ConvCurvCola
1. Open the chart “ConvCurvCola”.
2. Insert the component “MUL”.
3. Interconnect these as shown in the following figure.
Figure 3–12
Table 3–8
MUL Name MUL_Speed_ConvCurvCola
X2 -1.0

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Result
The device level is created in its entirety for the plant section “Plant3”.

You have reproduced the device level of the PCS 7 project in SIMIT in full and can
now execute the measuring point test.
Figure 3–13

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4 Modeling Physical Correlations
4.1 Establishing the Physical Process Model

The following section will describe how to reproduce the models of physical
correlations in the PCS 7 project “Bottling Plant” in SIMIT, using components from
the standard library, the FLOWNET library and a component created with the CTE
tool.
4.1 Establishing the Physical Process Model

The basic procedure for establishing a physical process model is described in
the application example “Simulation of a PCS 7 stirred tank reactor with SIMIT
simulation framework” (\4\) chapter 2 “Basics of Process Engineering”.
4.2 Model Plant Section “Plant1”

The following section will describe the development of the process model for the
plant section “Plant1”. The plant section “Plant1” describes raw material tanks and
injection into the reactors of plant section “Plant2”. The plant section consists of
three raw material tanks. The modeling is carried out for raw material tanks 1 and 3
with components from the standard library. Raw material tank 2 is created using
components from the FLOWNET library. Macros are created for calculations which
occur repeatedly.
4.2.1 Creating Macros
The following section will describe the procedure for creating the required macros.
Macro “LiterSTom3s”
The macro “LiterSTom3s” converts the volume flow from liters per second to m³ per
second. The procedure for creating this is described below step-by-step.
1. Switch to the Task-Card “Macros” in the Tools window.
2. Create a new macro.
3. Rename this macro “LiterSTom3s".
4. Open the macro.
5. Open the properties of the macro.
6. Assign the property “Code” the value “LiterSTom3s”.
7. Insert the component “DIV” from the standard library into the macro.
8. Assign it a suitable name (e.g. DIV_convert_Liter_s_to_m3_s).
9. Assign the input X2 the value 1000,0.
10. Connect the input “X1” of the “DIV” component to the sidebar for inputs.
11. Rename the input “L_s”.
12. Connect the input “Y” of the “DIV” component to the sidebar for outputs.

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13. Rename the output “m3_s”.
Figure 4–1
Macro “m3sToLiterS”
The macro “m3sToLiterS” converts the volume flow from m³ per second to liters
per second. The procedure for creating the macro is the same as the procedure
for creating the macro “LiterSTom3s”.
The following figure shows the components and their connection to the macro.
Figure 4–2
Adjust the properties of the macro and components as summarized in the table
below.
Table 4–1
Macro Code m3sToLiterS
MUL Name MUL_convert_m3_s_to_Liter_s
X1 Connection to m3_s
X2 1000
Y Connection to L_s
Macro “m3ToLiter”
The macro “m3ToLiter” converts the volume from m³ to liters. The procedure for
creating the macro is the same as the procedure for creating the macro
“LiterSTom3s”.

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Figure 4–3
below.
Table 4–2
Macro Code m3ToLiter
MUL Name MUL_convert_m3_to_Liter
X1 Connection to m3
X2 1000
Y Connection to L
Macro “PumpPress”
The macro “PumpPress” simulates the characteristic of a pump. The procedure
for creating the macro is the same as the procedure for creating the macro
“LiterSTom3s”.
Figure 4–4

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below.
Table 4–3
Macro Code PumpPress
AFormula Name AFormula_PumpPress
X1 Connection to
Pump_percent
X2 Connection to
Pressure_Gain
X3 Connection to Flow_X
Y Connection to Flow_X
Formula X1/100*X2*X3
Macro “ValveCurve”
The macro “ValveCurve“ simulates the equal percentage characteristic of a valve.
The procedure for creating the macro is the same as the procedure for creating the
macro “LiterSTom3s”.
Figure 4–5

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below.
Table 4–4
Macro Code ValveCurve
AFormula Name AFormula_ ValveCurve
X1 Connection to
Y_Valve_percent
X2 Connection to exp
Y Connection to Y_m3_s
Formula X3*pow(X1/100,X2)
DIV DIV_ValveCurve Connection to
Scaling_L_Min
X2 60000,0
4.2.2 Additional Preparations
Besides the actual models, components are also essential for the simulation of the
physical correlations as they can be used to set specific states. Separate charts
are created for these.

1. Create the folder “Misc” (from “miscellaneous”) in the folder “Charts”.
2. Create the chart “Connections” in the folder “Misc”.
Components and their connections which are used in this chart are described in
the following section.
4.2.3 Creating the Chart “RMT1”
The purpose of the chart is to simulate the physical model of the raw material tank
“RMT1”.
In the application example given here, the capacity of the raw material tank is
simulated according to the following formula:
= +
Procedure
The following section will describe the creation procedure.
1. Create a new folder in the folder “3_ProcessLevel”.
2. Rename it “Plant1”.
3. Create a new chart in the folder “Plant1”.
4. Rename it “RMT1”.
5. Insert the relevant components into the chart (see the figure below).

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6. Interconnect the components as shown in the following figure.
Figure 4–6
7. Open the chart “Connections”.

8. Insert the components shown in the following figure into the chart.
Figure 4–7
Table 4–5
BConnector Name BConnector_Fill_RMTs
DO_RMT1_Filling
OR Name OR_Fill_RMT1
11. Save and close the chart “Connections”.

12. Open the chart “RMT1”.
Table 4–6 Flow in RMT1

RS_FF Name RS_FF_Fill_RMT1
S OR_Fill_RMT1 OUT

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Selection Name Selection_Fill_RMT1
X1 100
ValveCurve Name ValveCurve_Fill_RMT1

exp 1
Scaling_L_Min 900
Table 4–7 Flow out RMT1

Connector Name NP111/Y
Connector Name NP1111_Red/Y
Connector Name FV111/Y
Connector Name NK111/Y
Connector Name RMT1_empty
MinMax Name MinMax_Pumps_RMT1
MinMax MAX
MinMax Name MinMax_Valves_RMT1

MinMax MIN
ValveCurve Name ValveCurve_RMT1
exp 1.0
Scaling_L_Min 500
PumpPress Name PumpPress_RTM1
Press_Gain 1.0
MUL Name MUL_RMT1_Out
X1 -1.0
Table 4–8 RMT1

ADD Name ADD_sum_flow_RMT1
INT Name INT_RMT1
UL 500.0
m3ToLiter Name m3ToLiter_RMT1
Selection Name Selection_RMT1_empty
X1 100
Connector Name LI111/PV
Connector Name RMT1_empty

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Table 4–9 Fill RMT1 finished?, For Dosing Control, Flow into Reactor1
m3ToLiter Name m3ToLiter_FD111/PV
Connector Name FD111_PV
Connector Name RMT1_to_Reactor_1
Compare Name Compare_Fill_RMT1_finished
X2 450.0
Comparison >
14. Save and close the chart “RMT1”.
“RMT2”.
= +
The chart “RMT2” is created using components from the FLOWNET library.
The FLOWNET library contains components for creating the simulation of piping
networks. You can find a detailed description of piping networks and components
in the FLOWNET library in chapter 7 “The FLOWNET Library” in the manual “SIMIT
V8.1” (\6\).
Procedure

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Figure 4–8

6. Insert the components with a red frame in the figure into the chart.

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Figure 4–9
Table 4–10
DO_RMT2_Filling
2x Connector Name NK123_V0/Hi
2x Connector Name NK123_V1/Hi
XOR Name XOR_RMT2_Left
AND Name AND_RMT2_Right
Selection Name Selection_RMT2_Left
X1 100.0
Selection Name Selection_RMT2_Right
X1 100.0
Connector Name RMT2_Left
Connector Name RMT2_Right


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PnodeLiquid Name PnodeLiquid_In_RMT2
Pressure 4.0
Valve Name Valve_Fill_RMT2
Cvs 55.0
ShowFlow True
ShowFlowDirection True
RS_FF Name RS_FF_Fill_RMT2
S OR_Fill_RMT2 OUT
Selection Name Selection_Fill_RMT2
X1 100.0
Table 4–12 RMT2

StorageTankLiquid Name StorageTankLiquid_RMT2
Volume 0.5
Height 5.0
LevelInit 0.0
Measurements Name Measurements_LI121

Valve Name Valve_NK121
ShowFlow True
Pump Name Pump_NP121
NominalPressure 4.5
NominalMassflow 3
ShowFlow True
Connector Name NP121/Y
Valve Name Valve_FV121
Cvs 30.0
ShowFlow True
PipeMeasure Name PipeMeasure_Dosing_control_FD121
ShowFlow True
JointLiquid Name JointLiquid_RMT2_Flow_out

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Valve Name Valve_RMT2_Right
ShowFlow True
Connector Name RMT2_Right
Topology Name To_Reactor_2
Valve Name Valve_RMT2_Left
ShowFlow True
PipeMeasure Name PipeMeasure_Flow_into_Reacor1
Measurements Name Measurements_Flow_into_Reactor
LiterSTom3s Name LiterSTom3s_Flow_into_Reactor1
PnodeLiquid Name PnodeLiquid_Flow_out_RMT2
Table 4–14 Fill RMT2 finished?, for dosing control

Compare Name Compare_Fill_RMT2_finished
X2 450.0
Comparison >
Measurements Name Measurements_FD121
12. Save and close the chart “RMT2”.
“RMT3”.
= +
Procedure
4. Select all of the components and copy them.
5. Close the chart “RMT1”
6. Insert the copied components into the chart “RMT3”.

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7. Remove the following components:

– Connector “NP1111_Red/Y“
– MinMax “MinMax_Pumps_RMT1”
– PumpPress “PumpPress_RTM1”
– ValveCurve “ValveCurve_RMT1”
– m3ToLiter “m3ToLiter_FD111/PV”
8. Connect the connector “NP111/Y” to the component “MinMax_Valves_RMT3”,
as shown in the following figure.
9. Insert the macro “LiterSTom3s” and connect it as shown in the following figure.
Figure 4–10

11. Insert the components with a red frame in the figure into the chart.
Figure 4–11

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Table 4–15
DO_RMT3_Filling
OR Name OR_Fill_RMT3

RS_FF Name RS_FF_Fill_RMT1 RS_FF_Fill_RMT3
S OR_Fill_RMT1 OR_Fill_RMT3
Selection Name Selection_Fill_RMT1 Selection_Fill_RMT3
ValveCurve Name ValveCurve_Fill_RMT1 ValveCurve_Fill_RMT3

Connector Name FV111/Y FV131/

Connector Name NK111/Y NK131/
Connector Name RMT1_empty RMT3_empty
MinMax Name MinMax_Valves_RMT1 MinMax_Valves_RMT3
Connector Name NP111/Y NP131/Y
MUL Name MUL_RMT1_Out MUL_RMT3_Out
Connector Name FD111_PV FD131_PV
LiterSTom3s Name LiterSTom3#1 LiterSTom3s_RTM3
Connector Name RMT1_to_Reactor_1 RMT3_to_Reactor_2
Table 4–18 RMT3

ADD Name ADD_sum_flow_RMT1 ADD_sum_flow_RMT3
INT Name INT_RMT1 INT_RMT3
m3ToLiter Name m3ToLiter_RMT1 m3ToLiter_RMT3
Selection Name Selection_RMT1_empty Selection_RMT3_empty
Connector Name LI111/PV LI131/PV
Compare Name Compare_Fill_RMT1_finished Compare_Fill_RMT3_finished

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The following section will describe the development of the process model for
the plant section “Plant2”. The plant section “Plant2” describes the reactors and
dosage into the reactors of plant section “Plant3”. The plant section consists of two
reactors. Modeling for “Reactor1” takes place with a reactor component created
with the CTE tool and with components from the standard library. “Reactor2” is
created with components of the FLOWNET library. Macros created previously are
used for calculations which occur repeatedly.
4.3.1 Preparation
The reactor component “StirredTankReactor” must be created with the CTE tool
first of all, to be able create the chart for the “Reactor1” process model in SIMIT.
You can find the model equations for the component “StirredTankReactor” in
the application example “Simulation of a PCS 7 stirred tank reactor with SIMIT
simulation framework” chapter 2.4 “Simulation of a process”. In the application
example given here, these have been adapted and simplified.
You can find information regarding the creation of your own components and
the syntax in the CTE tool in the "SIMIT - Component Type Editor" manual.
You can open the component “StirredTankReactor” with the CTE tool, look at
the source code and, if required, adapt it.
4.3.2 Creating the Chart “Reactor1”
The purpose of the chart is to simulate the physical model of the reactor
“Reactor1”.
Procedure
1. Create the folder “Plant2” in the folder “3_ProcessLevel”.
3. Rename it “Reactor1”.

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Figure 4–12

7. Insert the components shown in the following figure into the chart.
Figure 4–13
Table 4–19
BConnector Name Bconnector_RESET_Reactors
SR_FF Name SR_FF_RESET_Reactors
1. Close the chart “Connections”.

2. Open the chart “Reactor1”.

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Table 4–20
Connector Name Reactor1_Empty
MinMax Name MinMax_FlowOut_Reactor1
Parameter MIN
ValveCurve Name ValveCurve_Reactor1
Exp 1.0
Scaling_L_Min 50
PumpPress Name PumpPress_Reactor1
Connector Name TV211/Y
MinMax Name MinMax_Temperature_Reactor1
Parameter MIN
PTn Name PTn_Disturb_Temp_Reactor1
T 20.0
ADD Name ADD_Heating_Reactor1
X2 20.0
StirredTankReactor Name StirredTankReactor_Reactor1
SET Connection to
Bconnector_RESET_Reactors
OUT
Volume 1.2
Height 5.0
ULimit Connection to
SR_FF_RESET_Reactors R
Connector Name LI211/Y
Connector Name NK214_vent/Y
MUL Name MUL_Temp_Reactor1
X2 -1.0
PTn Name PTn_Vent_Reactor1
T 10.0
Selection Name Selection_Reactor1_Empty
X0 100

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Connector Name Reactor1_Empty
m3sToLiters Name m3sToLiters_Reactor1
ADD Name ADD_Temp_Reactor1
NOTc Name NOTc_INT_Reactor_LI311
IN Connection to Conv2 SensorA2
INT Name INT_LI311
Connector Name TC221/PV
4. Close the chart “Reactor1”.
4.3.3 Creating the Chart “Reactor2”
The purpose of the chart is to simulate the physical model of the reactor
“Reactor2”.
Procedure

2. Rename it “Reactor2”.

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Figure 4–14

6. Insert the components shown in the following figure into the chart (in a red
frame).

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Figure 4–15
Table 4-–
Selection Name Selection_RESET_Reactor2
X1 100
Connector Name RESET_REAC2
Compare Name Compare_TV221

X2 2.0
Comparison <=
Selection Name Selection_Cooling_Reac2
X1 100
Connector Name TempCoolingReac2
9. Close the chart “Connections”.

10. Open the chart “Reactor2”.
Table 4–21
PnodeLiquid Name PnodeLiquid_Inlet_RMT3_to_Reac2
Pressure 40.0
PnodeLiquid Name PnodeLiquid_for_Heating_Liquid
Pressure 50.0
Temperature 200.0
PnodeLiquid Name PnodeLiquid_for_Heating_Liquid
Pressure 50
Valve Name Valve_RMT3_to_Reactor_2
CVs 30.0
ShowFlow True

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Valve Name Valve_TV221/Y
CVs 360.0
ShowFlow True
Valve Name Valve_NK223/Y
CVs 360.0
ShowFlow True
Valve Name Valve_TempCoolingReac2
CVs 360.0
ShowFlow True
PipeMeasure Name PipeMeasure_RMT3_to_Reactor_2
Measurement Name Measurement_FD131
JointLiquid Name JointLiquid_Temp_Reac2

AConst Name AConst_Pump_Heating
Constant 100.0
JointLiquid Name JointLiquid_SUM_Inlet_to_Reac2
Pump Name Pump_Heating
ShowFlow True
HeatExchangerLiquid Name HeatExchangerLiquid_Reac2
VolumeTS 1.2
PnodeLiquid Name PnodeLiquid_HeatExange_Out
Pressure 0.1
StopValve Name StopValve_RMT2_to_Reactor_2
CVs 30.0
Topology Name To_Reactor_2
StorageTankLiquid Name Reactor2
Volume 1.2
Height 5.0
NbrOfStubs 4
Measurements Name Measurements_Reactor2
JointLiquid Name LI221/PV
MUL Name MUL_Reactor2
X2 -1.0
Connector Name NK224_vent
PTn Name PT1_Reac2_NK224_vent
T 10.0

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PTn Name PT1_Disturb_Reac2
T 10.0
ADD Name ADD_Temp_Reactor2
JointLiquid Name JointLiquid_Outlet_Reac2
Valve Name ResetValve_Reac2
CVs 360.0
ShowFlow True
Connector Name RESET_REAC2
PnodeLiquid Name PnodeLiquid_Reset_Reac2
CVs 3.0
ShowFlow True
Pump Name Pump_NP221
NominalPressure 4.5
NominalMassflow 1.0
ShuwFlow True
Connector Name NP221_Simo/Y
Valve Name Valve_FV221
CVs 0.5
ShowFlow True
PipeMeasure Name PipeMeasure_FD221
CVs 3.0
ShowFlow True
PnodeLiquid Name PnodeLiquid_to_Plant3
Measurements Name Measurements_FD221
NOTc Name NOTc_LI312
IN Connection to Conv2-SensorA2
OUT
INT Name LI132
UL 10.5
12. Close the chart “Reactor2”.

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At the current state of your project you can already test the program of the AS.
So far you have created all actuators and sensors in the folder “2_DeviceLevel",
and associated their inputs and outputs with the symbolic addresses. Besides this,
there are replicas of your plant's physical processes in the “3_ProcessLevel" folder.

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5 Simulation of the Conveyor System
5.1 Modeling the Goods Conveyed

In chapter 3 you created the conveyor system with the components from the
CONTEC library and derived the simulation of the drives with the function
“Generating the Device Level”. The following procedure describes how to
interconnect the sensors and model the goods conveyed.

The CONTEC library makes the relevant components available for the simulation
of the goods conveyed. These can be used to model the goods conveyed.
5.1.1 Creating the List of Goods Conveyed
An inventory of goods to be conveyed is compiled into a materials list for the

simulation. Proceed as follows to create this:
1. In the Project window, open the “Material" folder.
2. Double-click “New list”. A new list is created and opened in the workplace.
3. Open the “MATERIAL" folder in the CONTEC library.
4. Drag and drop the component “CBoxDS256” onto the workplace by holding
down the “Alt” key.
5. In the window “How many instances should be created?”, set the number to 10
and click “OK”.
Figure 5–1
6. Set the “SizeOfStorage" parameter for the goods conveyed to 8.

7. Save and close the list.

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5.1.2 Calculating the Color of the Goods Conveyed
In the application example given here, the goods conveyed constitute beverage
crates. Depending on the color of the beverage crate, the relevant drink is filled into
bottles. The component “BoxProperty” assists in assigning or reading the color of
the beverage crate. The component is not part of the CONTEC library and was
created using the CTE tool. The application example given here does not describe
the creation process.
Besides the component “BoxProperty”, the application example given here
contains two other components which are not part of a SIMIT library.
“CompareBox”
“CompareMix”
Component “BoxProperty”
The component “BoxProperty” invokes system functions which enable access to
the simulation of the goods conveyed. When the conveyed goods are created by
the “Conveyor” component in the CONTEC library, the conveyed goods are
assigned a unique ID. This can be read, for example, using the output
“SensorIdA1”. The component “BoxProperty” has read or write access to the
conveyed goods.
Note You can find information regarding the system functions of the CONTEC library
in chapter “7.3.4.3 System functions” in the manual “SIMIT (V8.1)”.
The “BoxProperty” component has the input “Id” which enables the sensor of the
“conveyor” component to read the Id. Furthermore, the component has the inputs
“READ” and “WRITE”. If the input “WRITE” is active, then the information present
at the other inputs of “BoxProperty” is written to the memory and the properties of
the conveyed goods. This includes the values for the inputs “R”, “G”, and “B”. With
these values, the color of the conveyed goods in the simulation is defined.
Note You can find information regarding the properties of the conveyed goods (e.g.
color of conveyed goods) in chapter 7.3.3.4 “Component types for the simulation
of conveyed goods” in the handbook “SIMIT (V8.1)”.
In the application example given here, an additional Id is written to memory which

represents the color of the goods conveyed.
Id “10” red
Id “20” green
Id “30” blue
If the input “READ” is active, then the memory of the item conveyed is read. Which
item conveyed is read, depends on the Id of the item conveyed. This is transferred
to the “BoxProperty” component with the aid of the “Conveyor” component sensors.
The information from the memory is written to the outputs of the “BoxProperty”
component and can be used there for further processing. The Color-Id is read in
the application example given here.

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“CompareBox” Component
The component “CompareBox” imports a number at input X. The outputs are
then written using the number. The outputs relate to the color inputs of the item
conveyed. Furthermore, the Id of each color is written to the output “Id”.
“CompareMix” Component
The “CompareMix” component imports the color-Id and reveals at the output
whether it is cola, orange-lemonade or a mix of both.
5.1.3 “Calc” Chart
The purpose of the “Calc” chart is to model the color of the item conveyed.
It contains the components described in chapter 5.1.2. Besides modeling the color
of the item conveyed, the conveyor system’s sensors also analyze the Ids entered.
The following section will describe the procedure for creating the chart.
Procedure
1. Create a new folder in the folder “ProcessLevel”.
2. Rename it “Conveyor”.
3. Move the chart “Conveyor_sim”, which you have already created (see chapter
3.2.2.) into the folder “Conveyor”.
4. Create another folder in the folder “Conveyor”.

5. Rename it “Misc”.
6. Create a new chart in the folder “Misc”.
7. Rename it “Calc”.
8. Open the chart.

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Figure 5–2
Table 5–1 Define box color and create box object on conveyor
Pushbutton Name Pushbutton_CreateBoxColor
DO_ConvSpure_S_AD
OR Name OR_CreateBoxColor
Counter Name Counter_CreateBoxColor
UL 3.0
CompareBox Name CompareBox_CreateBoxColor
BoxProperty Name BoxProperty
Id Connection to Conv1
SensorIdA1
WRITE Connection to Conv1
SensorA1
Pushbutton Name Pushbutton_CreateBoxColor
DO_PickUp
OR Name OR_CreateBoxObject
OUT Connection to Conv1
CreateObject

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Table 5–2 Read object ID and color ID from box object

BoxProperty Name BoxProperty_ReadIDs_Conv2_A1
Id Connection to Conv2 SensorIdA1
READ Connection to Conv2 SensorA1

CompareMix Name CompareMIX_Conv2_A1
Sin Connection to Conv2 SensorA1
OR Name OR_Cola_or_Mix
OR Name OR_OLimo_or_Mix
Input Signal 2_SignalLevel_PLCSIM_AS2
DI_Sensor1_Cola
DI_Sensor1_OLimo
DI_Sensor1_Mix
DI_Sensor2_Cola
DI_Sensor2_OLimo
DI_Sensor2_Mix
DI_Sensor3_Cola
DI_Sensor3_OLimo
DI_Sensor3_Mix
12. Save and close the chart “Calc”.

At the current state of your project you can test the automation of the conveyor
system.

Entry ID: 77362399, V1.0, 10/2015 57
6 Animation of the Crown Cap Machine
6.1 Creating the 3D Viewer Control

Besides the simple two-dimensional animation of graphic elements, SIMIT gives
you the option to create three-dimensional animations. The three-dimensional
animation of the crown cap machine is created below.
6.1 Creating the 3D Viewer Control

The 3D viewer control (Taskcard Control) is contained in the basic library of SIMIT.
3D animations can be created quickly and easily with this control, as it gives you
the option to import the geometry model of machines from a CAD system. The
import requirement is that the model has been exported in the format VRLM V2.0.
Note The description given here does not cover the generation of the geometry model.
You can find further information regarding the 3D viewer control and the data
format requirement in chapter 7.1.7.4 “The 3D Viewer Control” in the SIMIT
manual (V8.1) (/6/).
Procedure
1. Create a new chart in the folder “Conveyor”.

2. Rename it “3D_CrownCap”.
3. Open the chart.
4. Insert the component “3D viewer” from the task card “Controls”.
Table 6-1
3D-Viewer Name CrownCapMaschine
X 160
Y 15
Width 520
Height 695
3D model MASCHINE.wrl
Note The file “MASCHINE.wrl” belongs to the ZIP files

“77362399_PROJ_SIMIT_V81_Bottling.zip” which is available for download from
the article page.
6. Save and close the chart.

Entry ID: 77362399, V1.0, 10/2015 58
6.2 Creating the Animation

After you have integrated the geometry model of the machine into the 3D viewer
control, it will have various connectors (see properties of the 3D viewer control
“CrownCapMachine”). These can be used to address and animate the model.
For the animation, the movements of the individual machine parts are modeled
using standard library components. The animation begins as soon as a item has
left the conveyor line.
The following section will describe the procedure for creating the animation.
Procedure
1. Create a new chart in the “Misc” folder of the “Conveyor” folder.
2. Rename it “AnimationControl”.
3. Open the chart.
Figure 6–1
Table 6–2
Delay Name Delay_sonsor_z_axis_TY_move_back
RS_FF Name RS_FF_sonsor_z_axis_TY
OR Name OR_start_animation
IN1 Connection to Conv5 SensorA2
DriveV1 Name DriveV1_sonsor_z_axis_TY
MUL Name MUL_sonsor_z_axis_TY
X2 -5.0

Entry ID: 77362399, V1.0, 10/2015 59

Delay Name Delay_doors_close
T_ON 1.0
T_OFF 5.0
RS_FF Name RS_FF_door_sensors
DriveV1 Name DriveV1_door_sensors
MUL Name MUL_door_sensor_left_TX
X2 -5.0
MUL Name MUL_door_sensor_right_TX
X2 5.0
Delay Name Delay_sonsor_y_axis_TX_move_back
RS_FF Name RS_FF_sonsor_y_axis_TX
DriveV1 Name DriveV1_sonsor_y_axis_TX
MUL Name MUL_sonsor_y_axis_TX
X2 -5.0
Delay Name Delay_sonsor_x_axis_TX_move_back
T_ON 1.0
RS_FF Name RS_FF_sonsor_x_axis_TX
DriveV1 Name DriveV1_sonsor_x_axis_TX
MUL Name MUL_sonsor_x_axis_TX

X2 -5.0
7. Save and close the chart “AnimationControl”.

8. Open the chart “3D_CrownCap”.
9. Select the 3D viewer control components and adjust the properties according
to the table below.
Table 6–3
CrownCapMaschine Sensor_X-axis#TX Connection to
MUL_sonsor_x_axis_TX Y
Sensor_Y-axis#TX Connection to
MUL_sonsor_y_axis_TX Y
Sensor_Z-axis#TX Connection to
MUL_sonsor_z_axis_TY Y
Door_sensor_left#TX Connection to
MUL_door_sensor_left_TX
Y
Door_sensor_right#TX Connection to
MUL_door_sensor_right_TX
Y
10. Save and close the chart.

Entry ID: 77362399, V1.0, 10/2015 60

At the current state of your project you have created a 3D viewer control and
integrated a corresponding geometry model. In addition, you have created
animation for the 3D viewer control.
Configuration is complete at this point. The following section will introduce you
to the scripts and snapshots contained in the project.
In the example project given here, there are charts which contain other animations
with graphic elements and controls which are not described in the application
example given here. For this, some charts which were created throughout the
application example, were adjusted. These adjustments are optional and not part
of the description given here.
Note You can find information regarding graphic elements and controls in the SIMIT
manual (V8.1) (/6/) and in the application example “SIMIT Getting Started” (/3/),
in chapter 5 “Creating the graphical interface”.

Entry ID: 77362399, V1.0, 10/2015 61
7 Scripts and Snapshots
7.1 Scripts

The example project given here contains three scripts and a snapshot.
The following section describes the functions of the scripts and snapshots. Both
of these functions offer great advantages when developing an Operator Training
System.
7.1 Scripts
SIMIT gives you the opportunity to influence the simulation by using the Automatic
Control Interface with automated scripts. This allows you to create situations
such as the overheating of a reactor. Furthermore, scripts can be used to create
snapshots. This allows you to create a plant status with a script and then save it
as a snapshot. Furthermore, you can create log files with measurement values
for the period of time that a script is running. This allows you to determine, for
example, the operator reaction time required to prevent, for example, the
overheating of a reactor.
Creating Scripts
Scripts are created in the folder “Scripting” in the project window. These can
be created before the simulation starts or during the simulation. Changes can be
made to the scripts throughout the simulation. To create a script, open the folder
“Scripting” and execute the function “New script”. You can enter the commands in
the editor window and if the simulation is running, you can start the script using
the “Start script” button.
Note For detailed information about creating and starting scripts and commands,
please refer to chapter 6 "the Automatic Control Interface (ACI)" of the "SIMIT
(V8.1)” operating manual.
“LeanPIDTest” Script
A simple control test for temperature regulation of “Reactor1” can be carried out
using the “LeanPIDTest” script. After the script has started, a log file is created.
The start date and start time are recorded in the log file. A query appears to check
whether the target value of 10°C is set on the regulator. If the response is “yes”,
a plot of the actuating value is created for the valve TV211. After a period of
20,000 cycles, a disturbance of 10°C is added to the temperature value TC211
for another 20,000 cycles. At the end, the disturbance is removed and a snapshot
“Lean-OTS” is created.
Note The paths specified in the script can be adjusted, if required.

Entry ID: 77362399, V1.0, 10/2015 62
7.2 Snapshots
Script “Reactor1OverHeating”
The overheating of “Reactor1” is simulated using “Reactor1OverHeating”. After the
script has started, a log file is created. The start date and start time are recorded
in the log file. Then a disturbance variable is added to the reactor temperature.
The disturbance variable is only removed when the operator opens the valve
“NK214_vent” (in the WinCC Runtime). At the end of the script, the operator’s
reaction time is recorded in the protocol file.
Note The paths specified in the script can be adjusted, if required.
Script “Reactor2OverHeating”
The script “Reactor2OverHeating“ corresponds to the script
“Reactor1OverHeating”. Only “Reactor2” is heated and reacts to valve
“NK224_vent” being opened.
7.2 Snapshots
The snapshot “Lean-OTS” is included in the application example given here.
This was created automatically by the script “LeanPIDTest”. It can be created
manually using the function “Snapshots”. You can select this in the menu
“Simulation > Snapshots” by clicking the button “Snapshots” in the toolbar or in
the folder “Snapshots” in the project window.
You can retain the plant status in a snapshot and reload it as often as you like.

Entry ID: 77362399, V1.0, 10/2015 63
8 Commissioning
8 Commissioning
The commissioning procedure for the SIMIT and PCS 7 project is described in
detail in the application example “Simulation of a PCS 7 stirred tank reactor with
SIMIT simulation framework” (\4\).
Start the SFC “SFC_Master” in the WinCC figure “Plant1” after you have started
the simulation and the WinCC Runtime (see the following figure).
Figure 8–1

Entry ID: 77362399, V1.0, 10/2015 64
9 Related literature
9 Related literature
Table 9–1
Topic Title
\1\ Siemens Industry http://support.industry.siemens.com
Online Support
\2\ Download page of https://support.industry.siemens.com/cs/ww/de/view/77362399
this entry
\3\ SIMIT Getting https://support.industry.siemens.com/cs/ww/en/view/77362399
Started
\4\ Simulation of a https://support.industry.siemens.com/cs/en/en/view/93148023
PCS 7 stirred tank
reactor with SIMIT
simulation
framework
\5\ Process control https://support.industry.siemens.com/cs/ww/en/view/109474
system SIMATIC
PCS 7 PCS 7
read-me V8.1 incl.
SP1 (online)
\6\ Operating Manual https://support.industry.siemens.com/cs/de/en/view/93842565
“SIMIT (V8.1)”
10 History
Table 10–1
Version Date Modification
V1.0 10/2015 First edition

Entry ID: 77362399, V1.0, 10/2015 65

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Application description 10/2015

Simulation with SIMIT Simulation

Warranty and liability

Simulation with SIMIT and PCS 7 in a practical example

SIMATIC PCS 7 V8.1 SP1

Simulation with SIMIT and PCS 7 in a practical example

Conveyor System Simulation Chart ................................................................... 24

Simulation with SIMIT and PCS 7 in a practical example

7 Scripts and Snapshots .................................................................................... 62

Simulation with SIMIT and PCS 7 in a practical example

1 Task Description and Solution

plant", which you can find on the same article page.

Simulation with SIMIT and PCS 7 in a practical example

1.2.1 Overview of the complete solution

Simulation with SIMIT and PCS 7 in a practical example

Knowledge of control technology

1.2.2 Core Functionality

1.2.3 Hardware and Software Components

Simulation with SIMIT and PCS 7 in a practical example

Note SIMIT V8.1 is offered in three versions: "STANDARD", "PROFESSIONAL" and

Example Files and Projects

Simulation with SIMIT and PCS 7 in a practical example

2 Initial Work on the Project

2.1 Presentation of the Project

Task Description for the PCS 7 Project "Bottling Plant"

2.2 Configuring the PLCSIM Interface in the SIMATIC

Note The "BottlingPlant_MP" project includes two automation systems.

Simulation with SIMIT and PCS 7 in a practical example

2.3 Configuring the PLCSIM Interface in SIMIT

Assigning the Time Slice

Simulation with SIMIT and PCS 7 in a practical example

2.4 Verifying Communication between PLCSIM and SIMIT

2.5 The Current Status of your Project

Simulation with SIMIT and PCS 7 in a practical example

Simulation with SIMIT and PCS 7 in a practical example

3 Creating the Device Level

3.1 Creating a Template

Simulation with SIMIT and PCS 7 in a practical example

The following figure outlines these for the “AMON_Std”.

The template “AMON_Std” is created from the base template “AnalogMonitoring”

7. Change the name to “AMON_Std".

Simulation with SIMIT and PCS 7 in a practical example

11. Save and close the template.

Simulation with SIMIT and PCS 7 in a practical example

Block Signal / parameter

The following list comprises the properties of the components.

Simulation with SIMIT and PCS 7 in a practical example

Component Property Value

Create the remaining templates according to the procedure described above.

3.2 CMT Import

Simulation with SIMIT and PCS 7 in a practical example

5. Click "Import" to start the import.

Simulation with SIMIT and PCS 7 in a practical example

7. Execute steps 1 to 6 for the coupling “2_SignalLevel_PLCSIM_AS2”. Apply

Simulation with SIMIT and PCS 7 in a practical example

3.3 Generating the Device Level

3.3.1 Adapting the Template

The following procedure describes how to adapt the template “Bottling_MotorRev”.