Restricted © Siemens Industry, Inc. 2014 All rights reserved. usa.siemens.com/summit

Automation SummitA User Conference - June 23 – 25, 2014

Restricted © Siemens Industry, Inc. 2014 All rights reserved. usa.siemens.com/summit

John SullivanUtilizing Siemens Best Practices When Leveraging Existing Rockwell Code

Presenter InfoJohn Sullivan

Senior Project Engineer

Siemens Certified ProfessionalProfessional Engineer- Control Systems

B.S. in Mechanical Engineering

Rose-Hulman Institute of Technology

With DMC since 2009

DMC Company Profile

Industries Served:

Automotive

Chemical and Food

Processing

Electronics/Semicondu

ctor

Hydraulics

Laboratory Testing

Machine Tool

Material Handling

Metal Converting

Packaging

Pharmaceutical

Printing & Textiles

Established in 1996, offices in Chicago, Boston, Denver & customers throughout

the world

employees & growing

70+

Areas of Expertise

MANUFACTURINGAUTOMATION & INTELLIGENCE

PLC Programming

Motion Control Engineering &Servo Systems

HMI & SCADA Expertise

Intelligent Data& Web BasedSystems

Vision Inspection Expertise

Robotics

TEST & MEASUREMENT AUTOMATION

NI FPGA

LabVIEW Development

Test Stand Design

Machine Vision

Data Analysis & Reporting

NI Real-Time

CUSTOM SOFTWARE& HARDWARE DEVELOPMENT

PC Application Development

Product Development

Web Application, iOS, Android & App Development

Embedded Design & Programming

SDK, API & Driver Development

Database Systems

MICROSOFT CONSULTING SERVICES

10

10

5

5

INDIVIDUAL CERTIFICATIONS

Agenda

• Why Convert?• Types of Conversions

• Line by Line• Complete Rewrite• Selective Rewrite

• Specific Customer Situation

• Solution• Challenges• Benefits• Questions

Why Convert?

• Expand to new markets• Hardware/software

improvements • Match company

standards• Spec Job

How to Convert from Rockwell to Siemens?

How to Convert

from Rockwell

to Siemens

• Line by Line Conversion

• Complete Rewrite• Selective Rewrite

Line by Line

Line by Line: Pros

Straight Forward

Line by Line: Pros

Easy for Current

Programmers

Line by Line: Pros

Siemens ToolOn the Way

Line by Line: Cons

Breaks Best Practices

Line by Line: Cons

Usually Not Most Efficient

Line by Line: Cons

Potential for Weird Hang-

ups

Line by Line

Line by Line

Line by Line

Line by Line

Line by Line

• Pros• Straight Forward• Siemens Tool in

development• Easy for customers

familiar with current AB software to navigate

• Cons• Breaks Siemens

programming best practices

• Not most efficient for Siemens system

• Potential Hang-ups

Complete Rewrite: Pros

Best Practices

Complete Rewrite: Pros

IEC61131-3

Complete Rewrite: Pros

Optimization

Complete Rewrite: Cons

Existing Programmer

s

Complete Rewrite: Cons

Time

Complete Rewrite: Cons

Lost Legacy Knowledge

Complete Rewrite• Pros

• Can use best practices• IEC631131-3• Optimization

• Cons• Existing programmers difficulty• Typically more time consuming (but not

always)• Lost Legacy Knowledge

Selective Rewrite

The best tool for an AB to Siemens conversion is a experience person with expertise in both platforms.

Selective Rewrite: Pros

Best Practices

Selective Rewrite: Pros

Leverage existing

knowledge

Selective Rewrite: Pros

Engineer Ramp-up

Selective Rewrite: Cons

Requires higher level

design

Selective Rewrite: Cons

Missing some improvements

Selective Rewrite: Cons

Time

Selective Rewrite• Pros

• Implements some best practices• Leverages some of existing code• Some familiarity to existing code.

• Cons• Requires some higher level design to

pick and choose what to reuse• Some instances of not using best practices• Typically more time consuming (but not

always)

• Line By Line• Project is small and stable

(relatively few changes over time)• Complete Rewrite

• Customer is moving all machines to Siemens;investing training time to use Siemens hardware the best possible way.

• Anticipating regular hardware and software changes and machine upgrades

• Selective Rewrite• Customer has a lot of time invested in

existing code• Customer wants to maintain both lines

simultaneously.

How to Pick (guidelines)

Project Details

Customer Situation• OEM with existing equipment they had been

developing in Rockwell for 20+ years• Wanted capability to sell to growing Siemens

business in Europe and the Americas.• Had a large team of talented engineers very

familiar with AB, but new to Siemens

• Wanted to ensure best practices with Siemens hardware and easy maintenance for an AB and Siemens line

Selective Rewrite

What do we rewrite?• Rewrite

• Motion• Any repetitive code (and there was lots of it)

• Translate Directly• State Machine Decision Logic• Basic Alarm Signals

Motion: Servos• Utilized Open Motion Commands on S7-1516.• Looks and feels very similar to AB, which was

big customer plus.

Motion: Servos

Motion: Servos

Motion: VFDs• VFDs

• Utilized Telegram messaging.• Wrapped up Telegram messaging inside FB

to make change easier• Used because customer had more servos

and VFDs (axes) than the 1516 allowed (and didn’t want to upgrade PLCs)

Repetitive Code• Biggest opportunity for success• Keep in mind IEC 61131-3

Repetitive Code AB Sensor

Repetitive Code AB Sensor

New Code- Siemens Sensor FB

New Code- Siemens Sensor FB

Repetitive Code AB Cylinder

Repetitive Code AB Cylinder

Repetitive Code AB Cylinder

Repetitive Code AB Cylinder

New Code- Siemens Cylinder FB

Challenges

• Comments• Open Motion Number

of Axes• Keeping Code

Structure

Comments

Comments

• Customer wanted to use a 1516 for cost and capability.

• 1516 is limited to 20 Axes• Solved issue by using Open Motion Commands

for servos, and telegram messaging for VFDs running in speed control.

Open Motion Limits

• Due to the copy paste nature of the previous AB code they had arranged things different.

• A cylinder had logic in 3-4 different places.• Solution was to make 2 different FBs. One for

control and one for alarms to mirror code placement as best as possible.

Keeping Code Structure

A A

B

BC

C 

Project Benefits

For the customer…Leveraged 20 years of code and development

Eased training for field service team

Easy for customer to make changes to both product lines

General benefit…Allowed us to use the best features of the Siemens hardware

Eased the customer into the new software which improved their impression.

Final Thoughts & Questions?

Restricted © Siemens Industry, Inc. 2014 All rights reserved. usa.siemens.com/summit

John SullivanJohn.Sullivan@dmcinfo.com303.927.0191 www.dmcinfo.com

Connect: CNE