Implementation of a controller for redundant operation including the electrotechnical design, manufacture of the control cabinet and software development


The raw materials for glass production are combined and mixed in the glass manufacturer's batch house. During the course of a conversion, a so-called H Series controller was installed to allow redundant operation. The objective was to improve plant safety to eliminate or at least minimize production losses caused by the failure of individual systems. Furthermore, we developed a recipe structure and recipe management system using WinCC to allow central data storage. During the course of the work the weighing scale's electronic unit dating from 1970 was replaced with a state-of-the-art version from Siemens. Our services covered the entire electrotechnical design including the manufacture of the control cabinet and the development and commissioning of the PLC and PC software. The first step was to implement the H Series system and the new scale in the existing plant control system. The H Series controller and the recipe management system were designed for the expected final expansion level with five scales and two additional mixer controllers.


Glass and ceramics


The controller was integrated into the overall system and commissioned during a continuous production run over the course of seven days. Appropriate measures were taken to enable the system to be switched over from the old to the new controller during commissioning.

The system now has a user-friendly controller which displays the plant status. The transparency of the circuit diagram structure and documentation, the fail-safe controller and also the simple access to and reporting of plant data are further advantages that ensure increased plant safety and ease of maintenance. This enables raw-material consumption data based on the individual recipe and silo, daily and shift reports, and also batch, error and malfunction logs to be called up.

Technologies used:

  • Siemens S7-400H controller
  • Siemens WinCC client/server system
  • Decentralized connection via redundant PROFINET interfaces
  • Siwarex FTA electronic scale module from Siemens