How can the solar power industry eclipse previous efficiency standards? - Totally Integrated Automation: maximum productivity, efficiency and ...
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How can the solar power industry eclipse previous efficiency standards? Totally Integrated Automation: maximum productivity, efficiency and flexibility along the entire value-added chain Answers for industry.
Sunny prospects for the solar power industry –
with Totally Integrated Automation
There can be no argument that solar power is developing into one of the supporting
pillars of energy supply. At the same time, the challenges facing the solar power industry
are also increasing. The demand is for higher productivity, more powerful systems, first-
class equipment, etc. Only when they succeed in meeting these challenges can companies
benefit from the sector boom and enjoy sustained success against global competition.
Totally Integrated Automation (TIA) meets requirements here.
2
Totally Integrated Automation 04
More productivity along the entire Totally Integrated Automation is the ideal The levers for increasing
value-added chain basis for implementing customized auto- competitiveness 08
mation solutions – both for photovoltaic
The complete range of solutions
With Totally Integrated Automation, we as well as thermal solar power plants. In
for CVD reactors and systems 10
offer you an open system architecture every case, the unique level of integra-
that is perfectly oriented around re- tion guarantees perfect interplay of all Leading partner for the
quirements and trends in international components used, meeting requirements manufacturer of solar glass 12
markets. Our comprehensive, integrated for maximum efficiency and flexibility
range of products, systems, concepts and along the entire value-added chain. Integrated machine solutions for
services covers the entire automation manufacturing wafers, solar cells,
and solar modules 14
world.
More productivity in line and
factory automation 16
Field installation from A to Z 18
3
Totally Integrated Automation:
the intelligent answer to all requirements
Customers and international markets make demands that are constantly changing, expanding
and shifting focus. With Totally Integrated Automation, companies are perfectly geared to meet
all demands – and can respond quickly to changes when required. Below, we throw some light on
nt requirements for the solar power industry.
some of the more significant
Openness
With its uniquely open system
architecture, TIA offers you every
freedom in designing tailor-
made automation solutions.
For example, you can also
integrate systems from different
manufacturers easily into
your solution, and implement
expansions or upgrades.
International standards
All the products and systems
in our portfolio have been
developed and certified
in compliance with all the
necessary standards, and
the processes have been
appropriately audited. You can
thus be sure that your solutions
are always up-to-date and meet
all conditions – e.g. VDE, UL and
NEMA.
Process optimization
TIA meets the requirements
for perfect coordination of
processes, plant-wide or
Scalability/modularity
company-wide. The facility
TIA is the perfect response Flexibility
for constant optimization of
to strong fluctuations TIA enables maximum flexibility
processes makes you faster, more
in production and sales in structuring automation
efficient, and more productive –
volumes: with our scalable solutions and production
and thus guarantees the success
and modularly combinable processes. You can thus
of your company.
products and systems, respond to new requirements
automation solutions can significantly faster, more flexibly
be structured flexibly and and more cost-effectively –
aligned with new conditions without compromising quality.
at any time.
4
System features for maximum integration
and simple incorporation of expanded system
requirements
Totally Integrated Automation is characterized by six system features that support the complete production
process – throughout the entire life cycle. They guarantee maximum integration and simple incorporation of
expanded system requirements.
Engineering
With Totally Integrated
Automation, you back
maximum engineering
efficiency – in all life cycle
phases of the machine and
system. Within the scope of
an integrated engineering
environment, efficient soft-
ware supports you in all tasks
and ensures unique data con-
sistency over the entire engi-
neering process.
Communication
Consistent use of international,
cross-vendor standards meets
the requirement for unrestricted
integration in communication, Safety
and guarantees maximum data Safety tasks can be fully in-
transparency across all levels. tegrated into the standard
The relevant information is y,
control system or, additionally,
thus available system-wide at m.
into the process control system.
all times. The integrated overall system m
thus created offers countless
Diagnostics benefits and enables the
Highly efficient diagnostics implementation of innovative
concepts can be implemented solution approaches such as
easily – without additional wireless, fail-safe communica- Ruggedness
programming overhead. The tion via IWLAN and PROFINET. All standard products from our
hardware components auto- portfolio are characterized by
matically report any fault and Security maximum quality and rugged-
supply additional detailed infor- All the benefits resulting from ness. They are perfectly suit-
mation on its nature. Faults can the increased merging of the able for use in industrial envi-
thus be located and corrected automation and office worlds ronments, meet all the relevant
quickly and conveniently. can be enjoyed without restric- international standards, and
tion, because in response to have the appropriate certifica-
the resulting higher safety tion. Special product versions
requirements, we offer two are available for extreme envi-
complementary procedures: ronmental conditions.
“IT Security” (information pro-
tection) for protecting the pro-
duction system and data, and
“Audit Trail” for gap-free track-
ing and tracing of changes.
5
Convincing benefits throughout the entire
life cycle of machines and systems
With Totally Integrated Automation we set the course for optimized production. You benefit from
the perfect interplay of all automation components throughout the entire life cycle of the machines
and systems.
Planning and design
Intelligent tools support you in
selecting the right components
and in finding the optimal
design for your system – thus
ensuring maximum safety in
planning. In addition, system-
oriented, integrated engineer- Operation
ing minimizes costs for con- nication en-
Integrated communication
figuring and commissioning. ansparency
sures maximum transparency
Automation solutions can thus system-wide: plantt operators
be implemented significantly can thus respond significantly
faster, more safely and at lower exibly to fluc-
faster and more flexibly
cost. tuations in demand. d. Extremely
effective diagnosticscs concepts
Installation and commissioning mented, pro-
can also be implemented,
Consistent use of established ver for mini-
viding efficient lever
standards – like PROFIBUS and mizing unplanned downtimes.
Modernization
PROFINET, for system-wide Standardized operation of all
Existing systems can be adapt-
communication – reduces stations is also a system-wide
ed easily to changed require-
interface costs to a minimum feature.
ments, even during operation
and simplifies installation and in many cases. Continuity in
commissioning. Even the most Maintenance
the further development of our
complex systems can be imple- With intelligent maintenance
products and systems guaran-
mented in this way at signifi- strategies, potential sources
tees high investment security
cantly less cost. of faults can be detected,
in every case – by avoiding un-
analyzed and corrected more
necessary system barriers.
quickly – even via remote
maintenance. If modules have
to be replaced, this can be
done during operation with
many of our systems. Service
personnel benefit from the
uniform look and feel of our
components.
6
System components
for every task
With Totally Integrated Automation, Siemens offers the most comprehensive and
gap-free product portfolio in automation engineering.
Manufacturing Execution Systems ms
Integrated optimization of all cor-
or-
porate processes with maximum m
data transparency
Process control systems
System-wide, seamlessly inte-
grated automation and informa-a-
tion architecture
Industrial communication
Components for establishing an n
integrated communications infra-
ra-
structure across all automation
levels
Human machine interface
From HMI devices and visualization
tion
software right up to a SCADA sys-
ys-
tem for the most diverse tasks of Motion control
human machine interfacing Precision in the system for
Sensor systems
increased performance
Precision all along the line
Control systems
Comprehensive range of reliable Computer numeric control
Low-voltage switchgear
and powerful controllers for all The full range for all demands in
Power distribution for efficient
task areas mold and die making
energy use
Distributed I/O
Services
Whether standard or fail-safe:
The right support in every phase
the right solution for every
requirement
Drives
Products and solutions that make
machines more productive
7
The levers for increasing
competitiveness
With Totally Integrated Automation, you take a decisive step towards increasing
your competitiveness, because our open, integrated system architecture pushes
the precise buttons that take you straight to this target: productivity, efficiency,
and flexibility.
Feed Stock Products for Energy Conversion
Value Chain
Solar Industry
Photovoltaic MG Polysilicon
Cell-based Silicon Ingot brick Wafer mono, poly
TCSsynthesis CVDreactor
Photovoltaic
Amorphous silicon, compound
Thin-film Metallization Tempering of glass
Semimaterials, float/cast glass
Concentrated
solar power Glass substrate float
8More productivity of the future will not be covered across the spectrum.
We respond to this with solutions that drive progress
Maximum productivity along the entire value-added in solar technology, and ensure short engineering
chain is the highest aim in the solar power industry. times, maximum product quality, and efficient opera-
Another aim – to make solar technology readily tion – on your site and worldwide.
available to the general public – was added to this
only recently. This ambition will shape the future More flexibility
of the sector. What strategy will we use to achieve
this aim? Quite simple: reduce costs along the entire Short response times and flexible production are key
value-added chain and secure all investments. factors in increasing and securing competitiveness in
the solar power industry on a lasting basis. Perfectly
More efficiency coordinated processes along the entire value-added
chain reduce waiting times, backups, material inven-
Market requirements change in every sector with tory, and all operating costs. If all processes are fully
ever increasing speed. However, in the solar power synchronized, you can respond to changing require-
industry, not only do they change, but they will rise ments with maximum flexibility. On the following
continuously – and in the long term. Without the ef- pages, we provide you with an overview of the ben-
ficient operation of solar panels and without optimal efits offered by Totally Integrated Automation along
process control in the field, the energy requirements the entire value-added chain.
Field Installation
Cell mono, poly Glass assembly Module assembly On-grid power farm
On-grid rooftop
Thin-film coating Module assembly
Off-grid installation
Bending Mirror coating Glass tube receiver On-grid power farm
9Operator station 1 Operation station n Color printer Message printer Engineering station
Ethernet terminal bus
Industrial Ethernet
Automation Distributed I/O Reactor 1 Automation Distributed I/O Reactor n system bus
system system
ET 200M F ET 200M F
(Fail-safe) (Fail-safe)
ET 200M ET 200M
S7-400 (Standard) S7-400 (Standard)
Field devices Field devices
PROFIBUS
MV switchgear Transformer Busbar system Power controller CVD reactor
The complete range of solutions for
CVD reactors and systems
With the rising significance of renewable energy sources, the demand for polycrystalline
silicon (poly-si) for solar cell production will go through the roof in the next few years. As your
partner, we know what’s important in the manufacture of polysilicon, and within the scope
of Totally Integrated Automation, we are a one-stop shop for all your CVD reactor and system
needs: from the electrical equipment to the process control system.
10Tailored to maximum productivity world’s leading fieldbus, guarantees data exchange
between the field and ERP level – with a high degree
On the basis of our process and automation com- of standardization.
petence, we implement tailor-made solutions for
polysilicon manufacture. We work closely with our One-stop shop
customers, mechanical equipment manufacturers,
plant builders, and system integrators. Our solutions Our portfolio also encompasses all the electrical
make processes transparent and reproducible and equipment for your CVD reactors: the entire range
they enable verifiable documentation of quality of medium-voltage switchgear from 6 kV to 24 kV,
standards. The result is significantly more produc- as well as type-tested and certified SIVACON busbar
tivity in the entire manufacturing process. trunking systems for low voltage and medium
voltage from 200 to 2,000 V – everything tailored
The process control system for all requirements: to requirements in your manufacturing process. In
SIMATIC PCS 7 addition, Siemens offers cast-resin dry-type trans-
formers, matched to the process-related interests
The core of our solutions is SIMATIC® PCS 7. With its of the CVD reactor developer.
comprehensive industry-specific library of function
blocks, our process control system is at the heart of
successful polysilicon manufacture. It harmonizes
and monitors all subprocesses and offers modern
asset management that references the main process
and takes account of performance and equipment.
You thus have the entire “use history” of every in-
vestment in view, and you can protect your assets
and implement preventive maintenance measures.
SIMATIC PCS 7 enables limitless data exchange
across all levels – and it guarantees plant-wide en-
gineering from a central location. PROFIBUS, the
SIMATIC PCS 7
11Plant-wide
Integrated
Solutions Business Financial Enterprise
Management Controlling Office
Resource Planning
Ethernet
Material Information Energy Maintenance Manufacturing
Management Management Management Management
Ethernet
Execution System
Optimization
Engineering
Service
Operation Operation Operation Operation
Industrial Ethernet
Totally Control
Building
Solutions
AS-Interface
Video Processing
Batch Utilities Hot End Cold End Further Processing
Inbound Logistics Process Outbound Logistics
Leading partner for the
manufacturer of solar glass
The processes involved in solar glass production must above all be integrated and efficient. For
this reason, we offer individual concepts and systems that are all based on the principles of Totally
Integrated Automation. Together with our long years of expertise in the field of automation, this
holistic approach enables you not only to uncover synergies across all processes in glass production,
but also to put them to use.
Maximum quality in batch production assurance. Here are some examples from our
portfolio: weighing systems for proportioning
The quality of the batch is crucial to the quality the raw materials, and a wide range of mea-
of the end product, and that’s why the highest suring devices for level measurement – based
requirements have to be met in producing on ultrasound, radar or capacitive techniques.
the batch. For this purpose, we offer a coordi- Our range makes processes more integrated,
nated range of products – from drive technol- information and asset management more ef-
ogy, through field devices, right up to process fective, process control simpler, and above all,
control technology. Our range thus covers the it reduces operating costs.
areas of transport, proportioning, and quality
12Optimal processes at the hot end To ensure a tension-free glass stream, the cooling
process in the roller annealing furnace must be con-
Totally Integrated Automation ensures optimally tinuous and follow a pre-defined temperature pro-
coordinated processes at the hot end, and thus high- file. Our portfolio meets the requirements optimally
quality results. In the furnace, our portfolio sets the here: Our fault-tolerant drive systems thus ensure
course for maximum quality and energy efficiency – not only interruption-free driving of the vertical
for example, our precise measuring devices and con- shaft, but also efficient operation of the fans. Par-
trol valves, our separate controllers for controlling ticularly sensitive areas can be designed redundantly
the molten glass, or systems that reduce nitrogen here. We also offer solutions for precise, zone-by-
oxide (NOx) and all power consumption. Our zone heating of the glass stream in the roller anneal-
SIMATIC PCS 7 process control system controls, ing furnace. All components are, of course, seam-
for example, the glass status, the gas/oil flow per lessly integrated into the higher-level SIMATIC PCS 7
burner, the furnace pressure and the arch roof tem- process control system.
perature, and guarantees full integration and trans-
parency. Especially important control loops are
secured with backup concepts here.
For overall stabilization of the forming process, re-
sulting in lastingly high product quality levels, we
offer you a unique, comprehensive portfolio – from
drive solutions for top-rollers, through process in-
strumentation for temperature measurement and
gas analysis, to the SIMATIC PCS 7 process control
system for controlling all parameters. All compo-
nents can be integrated into the control system via
PROFIBUS DP.
Process instrumentation
13Integrated machine solutions for
manufacturing wafers, solar cells,
and solar modules
The production of PV and thin-film modules requires attention to different process stages with
different automation requirements. On PV modules, the spectrum stretches from slow processes
for silicon block casting, right up to high-speed machines for slicing the semiconductor wafers, or
the transport of individual components. On thin-film modules, the solar cells are structured using
laser technology – with maximum precision and speed. What matters in all these process stages is
maximum quality, as well as integrated processes and machines that set standards for precision.
14Wafer dicing Furnace process Module manufacture
SCALANCE SCALANCE
W788-1RR W788-1RR
PROFINET PROFIsafe PROFINET PROFIsafe SCALANCE PROFIsafe PROFINET
Industrial Industrial W788-1RR Industrial
Ethernet Ethernet MICROBOX Ethernet
SIMATIC 427C with
PVC Power S7-317 F WinAC RTX F
OFF/ON
ET 200S F SIMOTION
SINAMICS Controll SIMATIC S7
G 120 D Unit D410 modular embedded
SINAMICS
Basic Panel SIMATIC controler
S120
KTP600 ET 200pro
SINAMICS IWLAN
S120 E-Stop
DC-link Code Reading SIMATIC S7-300 F mit CPU 317 T
Buffer-Unit MV 440
Oven
Winder Feed Traversing
Machine solutions for manufacturing wafers,
solar cells and solar modules
The basis for highly productive machinery Motion control and drives
Within the scope of Totally Integrated Automation, From gears, through couplings and motors, all the
we offer all the components you need for imple- way to frequency converters and inverters from our
menting optimal machine concepts – for all process SINAMICS family of drives: we offer you a portfolio
stages. Our products and systems range from indi- for drive technology that is unsurpassed worldwide.
vidual sensors and actuators direct at the machine, Our drive systems cover all torque ranges, power
right up to distributed control modules and pioneer- ratings and voltage classes. Wherever motion control
ing solutions for human machine interfacing. plays a role, SIMOTION or the SIMATIC technology
CPU with failsafe is the first choice. Our scalable
Whether at the machine level or from a central loca- motion control system offers maximum flexibility:
tion: with SIMATIC, the core of Totally Integrated Depending on requirements, it enables centralized
Automation, we offer you the optimal controller or distributed machine concepts, as well as PC-based,
every time – modular, embedded or PC-based. There controller-based or drive-based solutions – user-
are, of course, versions available with integral safety friendly engineering and fast commissioning included.
technology.
Even when you’re dealing with distributed I/O, our
range covers all the angles: with SIMATIC ET 200M/
S/ISP/pro, we offer you a comprehensive range of
systems in standard and fail-safe versions.
SIMATIC
IC CPU 317TF-2 DP SINAMICS S120
15Integrated Engineering Clients
Solution DCS
Ethernet
Servers
PLC PLC PLC PLC
Embedded PC
Remote I/O Remote I/O Remote I/O Remote I/O Remote I/O
S7-300
Utility A Utility B Utility C Utility D Utility E
More productivity in line and
factory automation
As well as the actual manufacturing process, there are a host of applications in the solar power indus-
try for manufacturing end products – such as polycrystalline or monocrystalline silicon and thin-film
PV modules, as well as mirror and receiver glass for CSP (concentrated solar power) applications.
Several different systems are used for manufacturing these products. These frequently require
additives and operating materials – from raw chemicals and treated water, to preparatory measures
for the production sites.
Integrated automation from a single source to perform efficiently and economically when the
individual components actually come from the most
Heterogeneous production results in plants often diverse vendors. Another formidable challenge in
being equipped by a host of different automation non-integrated automation environments is the cen-
vendors. In many of these plants, the production tralized generation and analysis of operating data
data is forwarded and exchanged from different sub- from the different stages of the value-added chain.
areas over considerable distances and across com-
munication standards – a task that is very difficult
16Perfect interplay of all automation components Plant-wide communication based on field-proven
standards
Whether discrete automation with our SIMATIC
WinCC SCADA system or integrated automation on We offer you a comprehensive range of hardware
the basis of our pioneering SIMATIC PCS 7 process components for all readily available bus systems
control system: Totally Integrated Automation is such as Ethernet and PROFIBUS/PROFINET – with
characterized by its unique levels of integration, and integrated safety.
guarantees optimal interplay of all components and
subsystems. With our highly flexible solutions, you With the range for Industrial Ethernet, you back:
benefit along the entire value-added chain. As your • User-friendly safety modules
partner, we offer you everything you need for suc- • Infrastructures up to 1Gbit/s
cessful operation based on maximum production – • FastConnect cabling system
from a single source, and anywhere in the world. Our • Wireless communication
comprehensive portfolio is rounded off with turnkey
solutions for sub-areas in your plants, such as water Benefits of PROFIBUS and PROFINET:
supply and treatment, power supply and building • Real-time communication
automation. Working closely with you, we develop • Integral PROFIsafe technology, also wireless
and implement totally integrated automation envi- • FastConnect cabling system
ronments, tailored to your specific needs – solutions • Simple integration of PROFIBUS DP and
that reduce your production costs and optimize your PROFIBUS PA
processes.
Distributed I/O
17Field installation from A to Z
On the basis of our comprehensive range of automation components, we offer total concepts for
successful field installation. We offer everything here from planning support and engineering,
through power distribution and industrial automation, right up to information technology.
The optimal solution for every requirement Our solar inverters of the SINVERT grid infeed system
are perfectly suitable for medium to large-sized
Our range for field installation encompasses all the photovoltaic systems and solar power plants from
key components for automation – such as sensors, 10 KVA. They enable cost-effective infeed of solar
field communication, solar inverters, and complete energy into conventional power supply grids. Using
tracking solutions. For field communication, our port- master/slave combinations, you can implement any
folio enables, for example, wireless communication size of PV plant, from 60 KVA to outputs in the MVA
via PROFINET in conjunction with wireless LAN. This range – and you’ll reap handsome profits from the
significantly reduces the susceptibility of the whole cost-effective operation of your grid-tied PV plant
system to faults, particularly on open sites. Industrial over its entire life cycle.
Wireless LAN, based on the IEEE 802.11 standard, is
just as rugged, safe and reliable as a cable solution.
18Ethernet
SIMATIC S7-1200 SIMATIC library
Control center Solar tracker
The total solution for solar tracking applications Via the SIMATIC S7-1200 controllers on each tracker,
the dual-axis tracker units are able not only follow
Photovoltaic systems work most efficiently when the astronomical motion of the sun, they can also
solar radiation strikes the collector surface at as orient themselves to suit different climatic condi-
vertical an angle as possible and no shadows fall on tions. Remote control is also possible. Every CPU
the solar cells. However, solar radiation fluctuates contains a SIMATIC library via which an astronomical
not only according to weather, but also according algorithm is executed. The library is the core of this
to the time of day or the season of the year. For sys- application, with the position of the sun (sun vector)
tems where the panels or modules rest on movable determined precisely using an astronomical algo-
support plates, robust tracking systems can be used rithm. The library outputs the setpoints for control-
achieve almost maximum sunshine exploitation and ling the motors that move each individual support
thus power yield. For tracking based on astronomical plate.
specifications, this data is converted into individual
control programs that can be parameterized for
every site in the world.
SIMATIC S7-1200
19The information provided in this brochure contains
merely general descriptions or characteristics of
Siemens AG Subject to change without prior notice 04/10
performance which in actual case of use do not always
Industry Sector Order No.: E20001-A960-P200-X-7600 apply as described or which may change as a result of
Industry Automation Dispo 06303 further development of the products. An obligation to
P.O. Box 48 48 WÜ/26215 GI.AS.TA.XXXX.52.0.01 WS 04101. provide the respective characteristics shall only exist if
90026 NÜRNBERG Printed in Germany expressly agreed in the terms of contract.
GERMANY © Siemens AG 2010 All product designations may be trademarks or product
names of Siemens AG or supplier companies whose use
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