Page 1

The Bachmann Customer Maga zine 11|2016

TRUST ParTnErShIP: On Equal TErMS | MarITIME: EffICIEnT drEdgIng WInd: In BraZIl | InduSTrY: hIgh-TECh fOr PlaSTIC qualITY: ThE BaChMann EXPErIEnCE | nEWS: PrOduCTS and MarKET

Already at the end of the sixties, Niklas Luhmann, probably one of the most important sociologists of the 20 th century, put forward the thesis that our increasingly complex world can no longer function without trust: “Nobody knows precisely what will happen in the next moment. One must therefore have trust, both in people as well as in social systems in order to be able to act.” That was his view. Or as he otherwise described it in a more sensational way: “Trust is a risky credit advance.” This advance payment, this credit of trust, which you our customers, partners and suppliers give us every day is always in our mind. You should be able to trust us, but also our systems and solutions. The social scientist Dr. Gerhard Fuchs, for a long time a leading figure at the Stuttgart Center of Technology Assessment, once wrote in an essay: “In view of the increasing complexity of technical systems, know­ ledge is playing an ever decreasing role. Trust in technology is required instead.” How does trust work? And how do we experience it? We deal with both these questions in this edition of our customer magazine, which, as you may have noticed, now has a new look. I hope you enjoy reading this edition of the real.times – and also get some valuable insights into our Bachmann world. Yours sincerely,

Bernhard Zangerl CEO

real.times 11 | 2016

«Trust is not a cut flower that grows back.» Swedish saying

2 | 3




On location


gaTEWaY TO ThE WOrld



10 WhO TRUSTS WhOM? 11

VieWS oN THe SUBJecT of TruST

32 WHeN WoUlD YoU Ignorance ability

Ignorance desire


No awareness of the problem

Errors and mistakes


are we sure? do we know? Are we aware of our ignorance? Then trust makes action possible. It gives us the feeling of security that only someone who knows has. The person who is unaware of their ignorance, on the other hand, cannot trust. They are not aware of the problem. When to trust? This is the question we are faced with every day.

In his 2008 essay “The Relationship between Innovation and Trust” Bastian Pelka examines the issues of trust and security. He developed the above diagram based on the dissertation “Trust in socio­technological systems” by Barthel, Braczyk and Fuchs (1999).

hand OVEr COnTrOl?

33 VieWS oN THe SUBJecT of TruST




real.times 11 | 2016







On Equal TErMS





oNlY oNe THiNG coUNTS:







PlASTic BoTTleS:

a hIgh-TECh PrOduCT ThE CrEdIT


legal notice Editors responsible for the content Editing and layout Picture credits

Bachmann electronic GmbH, Kreuzäckerweg 33, 6800 Feldkirch, Austria, Frank Spelter up! consulting, Ruggell (FL) Bachmann electronic, Alewijnse, Van Oord, WEG, Soplar, Rittmeyer, Kraftwerke Hinterrhein, Thermo Fisher, GUP, CSR Wind Power, High Wind NV, Ulstein, privately submitted, iStock, Shutterstock, Fotolia

© 2016 Bachmann electronic GmbH; Subject to modifications


real.times 11 | 2016


On Equal Terms

How trust is important for Gerhard Bachmann Nearly fifty years ago – on March 1, 1970 to be precise – Gerhard Bachmann founded Bachmann electronic. A successful global ­company grew out of the one-man operation in the basement cellar of his private home. We spoke to the founder about his motivation and about what he considers his most important value.

Mr Bachmann, you once said it was sheer curiosity that was the basis of your ­business idea. Well, I don’t think I said it exactly like that. However, it’s right: The most important motivation at that time – and I think it is the same today for all involved – is a keen interest in technology and the endeavor to achieve perfection in control engineering. In the seventies, this was perhaps because we wanted to firstly make it interesting for many different sectors. Today it’s because we want to find answers as to how control engineering can simplify our future or make it at all possible. This, for example, is the case with wind power. However, all successes also involve set­ backs. This we have repeatedly experienced over the years. Our obsession with creating the ‘best controller’ was often ridiculed. Perhaps we were ahead of our time in many respects and didn’t always know where to apply our advances. And yes, we also learnt that even being shrewd and hard working is sometimes not enough.

6 | 7

What has characterized you and Bachmann electronic? As is often the case, it’s the difficult challenges that we repeatedly overcame with consider­ able effort that brought us further on – and this gives me tremendous satisfaction. It’s basically like climbing a mountain: The feeling of security and pride that comes from being able to trust in a team made up of different characters, whose solution expertise, tenacity and complementary skills still enable them to solve any task. And for this I am deeply indebted to my employees. However, this ‘wanting to be ahead’ is also an active feature of our business practice. It means we always work with the aim of providing solutions that can always offer a little bit extra. For us, supplying ‘products’ is not enough. Our deepest wish has always been to stand by our customers as partners, under­ standing and knowing their requirements – and developing jointly with them the optimum solution for their application.

You say that being able to trust a team also makes you proud. how important is trust for you in general? In my view, absolutely nothing is possible with­ out trust. It’s really the core of human dealing since communities cannot grow without trust. If you can’t trust your opposite number, how can any encounter take place on equal terms? This is the basis of any good relationship and in my view, applying it to our business, the basis for any progress. We won’t make any progress if we work separately. However, in a trusting and cooperative relationship it is possible to overcome any limits – and create fascinating technical solutions.

real.times 11 | 2016

«It's basically like climbing a mountain: The feeling of security that comes from trusting a team.» gerhard Bachmann founder of Bachmann electronic

Trust is the backbone of our company. Empathy, fairness and a good measure of modesty – towards co­workers, customers and suppliers – this is what we endeavor to practice every day. But I also think trust is always a kind of self understanding. Trust in oneself; in what you can do; in what you commit yourself to.

how do the customers of Bachmann electronic get to experience this? It’s clear to all of us that we have to earn this trust at the beginning of every new relationship and handle with care the trust that is repeatedly placed in us. Even if it may sound old­fashioned and counter to today’s ‘get more’ mentality. However, in the partner­ ships that we have we work by the principle of ‘serving before earning’. This also means that in the event of a fault – and regardless of its cause – our entire team works with the same intensity and commitment to rectifying the fault as the customer himself. Or to put it another way: We don‘t look for who‘s at fault but for solutions, and we are involved until the plant is running. This is how our customers know and also value us.

Summing up? I think you could describe our aims in one sentence: The basis of success is always total commitment to the customer’s benefit. And our customers can always rely on us thinking this way.

Many thanks for this interview. The Piz Buin is the highest mountain in Vorarlberg with a height of 3,312 m.





Menschen People with mita höherem high IQ tend IQ vertrauen to trust more, eher, probably was vermutlich because mit einer theybesseren have a better Menschenkenntnis understanding of people korreliert



FeuerwehrFiremen leute



Judges Richter



Bankers Banker



Journalisten Journalists



Politicians Politiker

expression of the prosocial disposition; GfK Verein (2015): Trust in professions

Vertrauen Trust by professional in Berufsgruppen group worldwide weltweit und andininEuropa Europeinin%%

face meets brown eyes; Kogan et al. (2011): Thin-slicing study of the oxytocin receptor (oXTR) gene and the evaluation and

Nach After2020Sekunden seconds kann it is man possible anhand to der assess Körpersprache whether beurteilen, you can trust ob a man stranger einem fremden Menschen vertrauen kann

Sources: carl, Billari (2014): Generalized trust and intelligence in the United States; Kleisner et al. (2013): Trustworthy-looking

Menschen Due to their mit facial braunen Augen features, wirken people aufgrund with ihrer brown Gesichtsmerkmale eyes appear vertrauenswürdiger more trustworthy

real.times 11 | 2016

Matter of Opinion

VieWS oN THe SUBJecT of


When your word is enough For me, trust is the good feeling to work together with a partner who is direct and open, who does not have a ‘hidden agenda’ or is retaining information – and who shares my enthusiasm. Therefore, trust is important. By placing our trust in someone, we don’t need documents or signatures. A person’s word is enough. Of course, facts like the technical com­ petitiveness of the supplied products or their reliability count as well. But in the moment I enter into a partnership, I have to place reliance on my counterpart. I would not invest my time and money in cooperation with somebody I do not trust. I think my perception of trust­ worthiness improved over the years. Today, I can better estimate if a relation­ ship is not as trustworthy as it should be – if the collaboration is not goal­ oriented, if politics and not the technical solution is in the foreground.

Katerina Xepapa Senior Development engineer, Research & Development at Damen Shipyards Gorinchem Netherlands

Trust changes with experience For me, trust means that I can have confidence that the person I am working with is reliable, fair and honest in what is asked of him or her. Personal expe­ riences primarily drive my trust or lack thereof. I tend to be more cautious in a professional setting regarding trust, though. I am in a leadership role and manage investments in my business. Due to this, I tend to be overly cautious with respect to trusting vendors and consultants that provide service to the business I manage judicially. In new experiences where an element of trust is needed, I try to approach partners professionally and address concerns before I engage in a trusting relationship. On a scale from 0 to 10, I was a 9 in trust early in my career. Due to professional experience and increased responsibility I have moved down to a 6 or 7 in the meantime, though. Personally, I have gone from a 6 to an 8+ with the people I know best.

Chuck Walker Partner of the energy operations Group llc, illinois, United States

also a matter of empathy Trusting others doesn't mean expecting absolute one hundred percent perfection – but confidence in being able to work together towards a successful outcome. Trust also means learning from the experience of others and thus improving one's judgement: If I can't trust a rope to which I wish to secure myself I also won't use it. In business the building of a basis for trust is also definitely a question of empathy. After that it's a question of the factors that are also conducive to a positive approach to a problem in order to find a joint solution. In my view, everyone has two chances in the beginning. If they fail the second time I draw my own conclusions. Winning trust again is then not a simple matter.

Joachim Smolka electrical design Klöckner DeSMA fridingen Germany

10 | 11


oNlY oNe THiNG coUNTS:

ThE BEST SOluTIOn. Three experts – and a common goal

The two Dutch companies Alewijnse and Van Oord together with Bachmann electronic have a lot in common: All three are progressive, independent family-run companies and are some of the best in their sector. They have been working together successfully for nearly ten years. The experts of the three companies know each other well. They also now have a new joint goal in sight: the control of two ships with trailing suction hopper dredgers.

real.times 11 | 2016

From 2017 two additional ships will be added to the fleet of the Dutch shipping company Van Oord. These are being built by the LaNaval shipyard in Bilbao, Spain: 158 m long, 36 m wide and with a load capacity of around 17,000 m³, these two giants are designed for coastal land reclamation worldwide and for providing pipe and cable routes for offshore instal­ lations such as wind farms.

Many participants The construction of a ship involves tasks and responsibilities over several stages: These kinds of special ships are often tendered by their future owners mostly years before the order is placed. The contract is then awarded to a shipyard which builds the ship as the project manager and implements the owner’s requirements. For this the shipyard selects the relevant system suppliers already while the tender is being drawn up and presents this to the shipping company before the contract is awarded. This requires the coordination of dozens of suppliers while the concept is being developed, for which the shipyard ultimately takes overall responsibility – for implementation in line with specifica­ tions and for keeping within the budget and the deadline.

Strategic partners The shipyard is free in all cases to select the systems and subcontractors to be used. However, for the implementation of special subfunctions, particular suppliers that the shipping company wishes to include are already stated in the specifications. For Van Oord, Bachmann is one of this kind of strategic partner. Bachmann has been implementing system solutions on Van Oord’s special ships since 2009. At this time the company had evaluated a new control system and found Bachmann’s M1 controller to be a system that meets both the processing speed requirements of the process control specialists as well as the hardware requirements of the automa­ tion engineers.

12 | 13

In Alewijnse's ‘Captain's Cabin’: Exchange between project partners (from left: Johan van Rikxoort (Alewijnse), Joeri ten Napel (Bachmann electronic), Theo Poorter (Van Oord), Elda Kavazbasic-Mulalic (Alewijnse))

Bachmann implemented Van Oord’s key requirements, such as the development of special interface cards with galvani­ cally isolated inputs or the porting of existing VMI-based systems. As Theo Poorter, process control engineer in the ship management department for ­process control at Van Oord, recounts, the close cooperation started from the very first m ­ oment: “I will always ­remember our first meetings as part of a training seminar at Bachmann head­ quarters in Feldkirch. We ­bombarded the engineers with qu­e stions and they answered every one.” One thing ­p articularly ­impressed him: “If they didn’t know something, they were also honest

real.times 11 | 2016

«Talks were not lengthy but always straightforward.» Theo Poorter engineer for process control at Van oord

in saying so. But they always returned to the seminar room a few hours later with the relevant specialists and presented the solution,” a smiling Theo Poorter recalls. “This is how we have repeatedly experienced Bachmann over the years: Talks were not lengthy but always straightforward.” Better, faster and cheaper With the two ships now built it’s always the one thing that matters: How can the work carried out with them be completed better, faster and more economically. It must therefore also be possible to further develop applications on these special ships, since the service life of a

ship is around 30 years. The trust placed in the selected suppliers and the future security of the systems used here is like a life insurance for staying competitive with this kind of ship over such a long period. The shipyard found Alewijnse to be a system supplier that has a thorough grasp of this business. The Dutch system integrator responsible for the development and construction of elec­ trical equipment on ships has extensive experience in the field of dredgers – and is well acquainted with the Bachmann M1 system through its experience from other applications. “It was therefore also easy for us to meet the shipyard’s

requirements in terms of the desired use of the Bachmann components,” explains Johan van Rikxoort, product manager for dredging and offshore at Alewijnse. Alewijnse also thinks it has the security needed with regard to the required future investment security: “Bachmann will soon have been in the business for 50 years, the technologies in use are being continually further developed, are always state­of­the­art, are provided with the necessary certificates for shipbuilding – and will be available for many years to come,” Johan van Rikxoort confirms.

14 | 15

«Find someone who is in the same boat as you and everything is possible.» Johan van rikxoort Product manager for dredging and offshore at Alewijnse

158 m long, 36 m wide and a load capacity of 17,000 m³: both new ships with trailing suction hopper dredgers for Van Oord. Both suction pipe installations can be seen on the right and left of the deck. Each ship has a crew of up to 38.

real.times 11 | 2016

Joint solution for ambitious plan From the planning stage to the launch of the ship, many years are spent onshore. The system suppliers were nevertheless faced with an ambitious time schedule. “As always,” explains a smiling Elda Kavazbasic­Mulalic, lead engineer and project manager at Alewijnse. “Of prime importance was naturally how the project could be developed and completed better and faster together.” The three companies and all involved already knew each other from other projects and we soon found that we shared one thing in common: “The simple fact that we all have the same goal. This enabled us to find solutions that would not have been possible on our own,” as Johan van Rikxoort adds.

More together Alewijnse thus not only added particularly useful functions to the specifications “in passing”, but also created a highly efficient redundancy solution that surpassed what was originally intended. “The dredger controller integrates over 2,500 I/ Os – a level of integration that shouldn’t be underestimated. Any subsequent maintenance work in severe conditions is thus also accordingly dif­ ficult,” Elda Kavazbasic­Mulalic outlines one constraint. Wiring plans and other technical information were consequently stored in the operator system for each Alewijnse module, thus considerably simplifying any troubleshooting during operation.

new technical solution Each day that a technical fault prevents this type of ship from operating is tremendously expensive. No wonder that the client placed particular importance on the redundancy solution proposed by Alewijnse and Bachmann, and the required availability, CPU performance, communication speed and fault tolerance ensured by this design. Although this type of solution imple­ mented was new for shipbuilding, “this was not a problem for us,” says Van Oord’s representative, Theo Poorter, adding: “We trusted each other that this solution would work and offer us the highest level of performance. There was no need for a contract. When everyone pulls together, any problems are also shared and solved together.”

Same culture, same objective Alewijnse’s Johan van Rikxoort also had the same view: “The corporate culture of our three companies is similar in so many respects. Communication between us is open, we share each other’s know­how – and ultimately also our daily challenges.” In other words, “each party always brings some added value.” He also notes another important point with regard to trust: Transparency. “We know at all times the current development and production status of the system components supplied by Bachmann, and are thus kept in the picture at every step. Furthermore,

16 | 17

Extremely helpful function in the hMI: Important system details (such as interactive descriptions of the I/O modules) are stored in the SCADA system. This reduces the time required for commissioning or troubleshooting in the event of a malfunction.

whenever a decision has to be taken, decision making channels are short and each party feels committed to the agree­ ment made.”

Trust as the key to success “Never before was a ship built in this way – and neither will one be built like this again. Each subsystem is an individual solution. As there is no series production there is no routine safety system either.” This is how Johan van Rikxoort describes his work environment and the new and unknown challenges that he has to face together with his automation team each day. Taking the entire risk assessment and choice of possible fallback solutions into con­ sideration, however, one thing counts for him above all: “You must trust your experience – and that of your partners.” Or as he otherwise puts it: “Find some­ one who is in the same boat as you and everything is possible.”

Extensive installation: The control system installation on both special ships consisted of 26 switch cabinets in total. The switch cabinets are assembled in Alewijnse's factory and shipped to the shipyard prewired.

Alewijnse Marine Systems based in Nijmegen, Netherlands, is a complete system supplier and system integrator supplying control solutions and electrical equipment for ships. The family­owned company was founded over 125 years ago and has around 1,300 employees worldwide.

Van Oord is one of the leading companies in the field of dredging, marine engineer­ ing and offshore projects (oil, gas and wind). The family­run company is head­ quartered in Rotterdam, Netherlands, and has over 5,000 employees worldwide and a fleet of over 100 special ships.

real.times 11 | 2016

Bachmann’s Contribution

Both MH Series Bachmann CPUs, which are run in hot standby mode as the main control­ ler for the suction hopper dredger, and seven other remote controllers with an MC205­CPU are connected in a redundant ring topology. To meet the extraordinary climatic and mechanical stresses to which installations on ships are exposed, all controller systems consist of Bachmann ColdClimate modules. The bluecom protocol used is ideal for this type of communication: It provides the

necessary throughput to enable the fault tolerant exchange of large data volumes in short cycles. The Van Oord VODAS process controller enclosed in an industry PC exchanges only the required parameters with the two main controllers via an SVI interface. The OPC UA server is also installed directly on the Bachmann MH­CPUs, and provides the connection to Alewijnse's SCADA system.

SCADA client

Master controller A

SCADA server

SCADA server

OPC UA client

OPC UA client

OPC UA server

OPC UA server


Hot-standby redundancy

Network redundancy


Network redundancy



Master controller B

18 | 19

ÂŤThe personal contact and the open mutual exchange are important to me. This is how quality is ensured.Âť

andrea Moritz Production manager at Bachmann electronic GmbH

real.times 11 | 2016


The Credit


Production manager Andrea Moritz talks about quality – and her aim to make Bachmann an experience.

Products and processes are becoming increasingly more complex, whilst the same high standard of quality is required. As head of the Supply Chain ­Management and Production department at Bachmann, Andrea Moritz, knows what an important role trust has – in the product, the processes, and naturally between people. What is quality and when is it good? By definition it is the state in which something has ­particularly good properties and is therefore valuable. For ­Andrea Moritz this means quite simply: “That I can rely on something 100 percent.” However, this doesn’t just apply to the product alone but every­t hing associ­ ated with it. From the process and supply quality right through to customer service – quite simply “the e ­ ntire Bachmann experience,” Andrea Moritz explains. Quality is thus firstly a promise. “Every customer that buys from us firstly gives us a large credit of trust, of which we here are well aware,” says Andrea Moritz, “and justifying this trust is our daily motivation.” But what does this need?

Self criticism as a motivation For Andrea Moritz the willingness to practice pro­ active and continuous improvement is essential – in all areas. “We don’t wait until there is a fault or until we get some negative feedback,” she e ­ xplains. ­Regular self measuring and investing time in ­a nalysis if the set targets are not reached, these are the critical factors on which improvement depends. It doesn’t matter if this is to do with product quality or PPM error rates. For Moritz, the CIP (continuous improvement) process that has also been introduced is a key aspect of quality improvement. “Our aim was for the continuous improvement approach to be ­t aken up by the entire workforce in all ­a reas, so

20 | 21

«Without the trust of my employer my work would not be possible.»

that all employees are trained in what it actually involves,” Andrea Moritz says. A collective goal for which one thing above all is essential: trust in the employees.

‘People first’ Whilst this maxim now seems somewhat overused, it is nevertheless absolutely correct and important: People first and thus mutual trust between the individual employees and areas. For Andrea Moritz this is a key factor in working together: “If the personal level isn’t sorted, every­ thing else will simply never function,” she explains. In this respect the size of the company is particularly beneficial. “In a large company people mainly only know those with whom they have direct contact in their work. Here at Bachmann this has a completely different quality.” Moritz knows all her 160 co­workers by name. “Because it is important for

me to know who I am dealing with,” she says. So every jour fixe meeting with department managers starts with issues about personnel first of all. She finds out how people are getting on in their environment, whether anyone was ill or whether there were any accidents. Only then are the individual processes, figures and similar topics discussed. “Naturally line managers must be able to trust their employees, but also vice versa. There is nothing worse than unpredictable line managers,” says Andrea Moritz and adds: “Mutual exchange is enormously important and I try to invest as much time in it as possible.”

Close relationship with the customer However, the SCM and production manager not only invests time in the collaboration with her employees but also with the customers, many of whom

have been placing their trust in Bachmann for many years. Andrea Moritz thinks that the reasons for the high customer loyalty and the associated credit of trust are to be found in many areas. “Our product quality, the reliability of our components – all of this certainly plays an important role. Of this there is no doubt. However, I also consider the conventional soft facts, such as personal contact, to be enormously important,” she explains. Knowing precisely who is behind the product, and taking the customer require­ ments into account – being able to offer these services is particularly important for Andrea Moritz and her employer. Regardless of whether it’s to do with personal dealings, sufficient stock levels or the one hundred percent traceability of components. “These measures are naturally costly, but being able to offer a good service simply is what Bachmann and I personally are about.”

real.times 11 | 2016

a matter of trust For Andrea Moritz, the job is basically a real personal issue. Coming originally from the field of business administration, already as a child and later as a student she was always close to technology and production. Having spent a few years working for a large company and overseas, it became time for her to face a new challenge. She therefore joined Bachmann four years ago, firstly as the manager of the supply chain manage­ ment department at Bachmann. After the merger of the SCM department with production, she was offered her current position as SCM and production manager by the company management. “For me this was a wonderful expression of trust. To experience the feeling of ‘you can do it, do you want to?’” says Moritz. A gesture that demonstrates how the company thinks and the values it represents. A decision was taken that didn’t depend

on study, age or even gender, but due to the trust in Andrea Moritz and her qualifications. She has been working in her current position since the beginning of 2015 and finds two things particularly attractive. Firstly the working together with other people. “My current job requires me to work with a really wide range of different people. The variety is really interesting,” Moritz explains. It also represents the opportunity for a professional company to further develop. “I don’t have a job that allows me to sit back in my chair,” she says and adds: “Logistics and production – these are my absolute pas­ sion. Being allowed to be a driving force gives me a great deal of pleasure.”

Trust creates quality creates trust In the future she will primarily focus on the joint goals set. After all, trust in the product also comes from quality, which in turn comes from good (team) work. It seems that Andrea Moritz has found pro­ fessional satisfaction: “I simply love the job and am really happy in my position. Without trust I certainly would not be able to work so freely.” Quality is there­ fore primarily a matter of trust – from the manufacturing of the product to the customer.

22 | 23

大 都 市 上 gaTEWaY TO 海 ThE WOrld On location

Bachmann China-Headquarter in Megacity Shanghai

Shanghai is the economic center of China, a booming industrial city and a real megacity. The Chinese metropo­ lis now has a population of 23 million inhabitants, which also includes many skilled foreign workers. Ten years ago, Shanghai‘s harbor became the largest freight harbor in the world – with over 800 million tons of freight handled every

year. Two international airports and the good connection to the rail network make the town an important transport hub in Asia – and literally the ‘gateway to the world’. Bachmann electronic China has been headquartered in Shanghai for 10 years and is thus at the heartbeat of

real.times 11 | 2016

the economic and technological progress of the country. Together with the branch in Peking in the north of the country, Bachmann takes care of its customers directly on location in the whole of China and thus ensures a reliable service and the fast supply of products.

24 | 25




As a result, this creates the need for reliable wind turbines with accurate status monitoring. Brazil has for a long time relied on hydropower for electricity generation. In recent years this type of energy generation has been severely impeded by increasingly longer periods of drought. This meant that a sufficiently secure power supply could no longer be ensured. For this reason, the government encouraged the use of alternative energy sources such as wind power. The hard background conditions in the energy market are placing demanding requirements on the operators and system manufacturers.

real.times 11 | 2016

Energy mix in Brazil today and in 2020





Development of alternatives to hydropower 12% 10% 8% 6% 4% 2% The problem with water Brazil is the seventh largest economy in the world and has an installed total output of approx. 143 GW. Hydro­ power dominates the energy mix of the country’s 203 million population, and represents 64% of the installed power. However, the strong concentration on this energy source has gradually brought with it problems as well as benefits. The power supply is threat­ ened particularly in the summer by periods of drought. In these periods, electricity from thermal power stations at a 60% higher price has to be connected to maintain the power supply. If this is not enough, this




Mineral oil



Wind power

Nuclear power

Natural gas


results in blackouts in the worst case. This was particularly the case when it last happened in 2001: Due to the largest energy crisis in Brazil in recent decades electricity had to be rationed. Water sources have largely been exhausted apart from the Amazon region, and the disturbance to the eco


system is increasingly being criticized by environmentalists. Fish stocks are suffering on account of the interven­ tion in the relevant waterways, rivers have to be provided with barrages, dams built and villages resettled. The connection to the power stations far away from the population centers also presents a challenge.

26 | 27

«A person who trusts is in no way irrational. Trust is rather the basis for handling and overcoming risks.» dr. gerhard fuchs Professor for Social Sciences at the University of Stuttgart

For this reason alternative renewable resources to hydropower are on the increase. The use of wind power is partic­ ularly suitable for Brazil. The seasonal way in which the large hydropower stations in the interior of the country and the wind power plants in the northeast complement each other is unique in the entire world. When the wind is blowing in these regions, there is little rain. In the rainy season on the other hand, there is less wind. Another benefit of wind power: Wind turbines can be built cheaper and faster than thermal power stations.

hard fought market Around three quarters of renewable energy is traded in state auctions through long­term supply contracts (for details see Factbox “Electricity trading in Brazil”). Operators of wind power plants are faced with several challenges here. On the one hand the intense price com­ petition between the operators. On the other hand, the fact that the prices for solar power, although still more expensive,

are gradually falling. This puts additional pressure on the price. For the consumer market and industry to continue growing as optimally and quickly as possible, the best price is the only factor that counts in these auctions. This trend has an effect on quality: Wind turbines with a total capacity of 800 MW have already been built, even though a distribution network to connect up the plants is not yet available. A further 400 MW are unused because although there is a grid, the turbines are not connected to it, some because of planning errors. Brazil has now learnt from the past: In future, operators can only make offers if the grids have already been planned. They must also bear the financial risk if the plant is not connected to the grid – even if another operator is responsible for the delay in grid expansion. One mandatory requirement for suppliers is also to guarantee a national production quota of the plants of at least 60%. This drives costs up but is nevertheless a requirement for operators to be at all approved and obtain credits from the Brazilian development bank.

real.times 11 | 2016

2014 under construction Total: 10,026 MW

351,9 MW 351.9

951,6 MW 951.6

Source: ANeel

2014 in operation Total: 3,461 MW

28 | 29


2 325,7 MW 2,325.7 MW

3654,2 MW 3,654.2 MW 69 MW

534,5 MW 534.5 34,5 MW 34.5

3320 MW 3,320 MW

2.5 2,5 MW MW

236.4 236,4 MW MW

1,978.9 1978,9MW MW Electricity trading in Brazil The energy market in Brazil is divided into regulated supply contracts (approx. three quarters) and freely negotiated supply contracts (approx. one quarter).

28,1 MW 28.1

2,5 MW 2.5

236,4 MW 236.4

1 978,9 MW 1,978.9 MW

With the freely negotiated contracts on the open market, the customer and the supplier negotiate the electricity prices directly. Consumers with a minimum power demand of 3 MW are able to use this option. With regulated contracts, different energy sources are negotiated in state auctions in the form of long­term supply contracts with different supply dates. The basic requirement for operators is a national production quota of at least 60%. This therefore supports Brazil's intention to be as self­sufficient for energy as possible.

28.1 28,1 MW MW

Always keeping the complete overview with Wind Power SCADA – from the entire wind farm to the detailed turbine status.

Reliability is mandatory Due to these requirements there is little room for servicing and maintaining the wind farms, let alone ensuring quality. This presents considerable challenges for the manufacturers of wind t­ urbines. They have to ensure maximum a­ vailability and productivity of the plants whilst keeping maintenance requirements at a ­minimum. This requires the use of highly reliable subsystems. Operators also require an accurate and clear overview of their entire wind farm and the associated load flows. However, they also need to be able to determine when necessary the actual and precise condition of each individual turbine.

Designed for the Brazilian market The challenges presented by these background conditions in Brazil have been met by the Brazilian c­ ompany WEG. Since 2013 WEG has been ­producing wind turbines and putting them into operation. With 70% of the local content, WEG meets the neces­ sary r­ equirements in order to take part in state a­ uctions. Together with the US ­company ­Northern ­Power ­Systems, which ­specializes in the design of wind turbines, the manufacturer developed a 2.1 MW turbine, equipped with a perma­ nent magnet synchronous generator. After this was successfully established on the Brazilian market, WEG started

with the development with a­ nother more powerful 3.3 MW turbine. This is specially ­optimized for the Brazilian market and will be ready for the market in 2017. For the new system generation WEG looked for a high-end SCADA system for the wind sector which can display the entire wind farm reliably and compre­hensively. WEG found Bachmann’s Wind Power SCADA (WPS) to be the right solution.

real.times 11 | 2016

The Bachmann Contribution

WEG had already used Bachmann's M1 controller system for the automation of the 2.1 MW turbines. After having had a positive experience with it, WEG also relied on Bachmann to supply the SCADA system for the 3.3 MW turbines and decided to use the flexible Wind Power SCADA system (WPS).

WEG is a multinational group with 30,000 employees. The company head­ quarters is located in the federal state of Santa Catarina, Brazil, and WEG has subsidiaries in 33 countries all over the world. The product portfolio covers motors and automation technology for electricity generation and power distri­ bution. Complete turnkey projects are also carried out. Founded in 1961, the company has focused on the production and installation of wind turbines since 2011 and has been supplying series systems since 2013.

WPS enables the monitoring of a complete wind farm on the border with Uruguay, consisting of 12 turbines and a central main station for communication with the operator. Through the WPS system the operator has a precise over­ view of set and actual load flows, enabling them to respond accordingly. The overview is thus provided in the SCADA level, for the turbine automation as well as for the control of the wind farm. Aldo Bravo Vacaflores, head of Operation and Maintenance at WEG is also impressed: “The control systems and software solutions supplied by Bachmann made this success possible.” Besides the overview display of the wind farm, WPS also enables detailed condition analysis for the individual plant turbines. WPS provides data in tabular view or graphically, and through the HTML 5 technology is ideal for web appli­ cations and the mobile display of data. All data is stored according to IEC 61400­25 on a central SCADA server and is thus always available. Customers like WEG particularly appreciate the openness of the system. Requirements that repeatedly occur can be implemented flexibly and quickly by the plant manufacturers themselves.

30 | 31

The future of mobility is repeatedly linked with the question of autonomous driving. Without trust (in the technology), however, this can never be reality. Never­ theless, almost three quarters of drivers in Germany would already be basically open to handing over control to the car in certain situations.

63 63% %

9% 9% Imtown In Stadtverkehr traffic


7% 7% During Während theder entire gesamten journey Fahrt


45 45% % In a traffic Im Stau jam

27 % 27%

15 15% %

Nie Never

In flowing Im fließenden Autobahnverkehr highway traffic

1,000 people over 18 years of age in Germany. Multiple answers possible.

Beim When Einparken parking Source: Bitkom Research (2015): Future of Mobility. Representative survey of more than

37 % 37%

of derthose Befragten questioned können can sich imagine vorstellen, buying ein Auto a car zu kaufen, that drives das itself selbständig fährt

real.times 11 | 2016

Matter of Opinion

VieWS oN THe SUBJecT of


Prerequisite for relationships Trust is a natural thing. It gives me confidence that what is expected will happen. I truly believe that trust is required for relationships to occur. Especially in situations in which risk increases, trust has to be consciously given to greater degree. I’ve experienced betrayals of trust in my life from time to time. Due to this, I’ve become more wary of giving trust. If some­ body betrays the confidence I placed in him or her, I usually withdraw trust and it takes quite a long time that I can confide in this person again. Nevertheless, on a scale from 0 to 10 I guess I am still an 8 in trusting others. And I think I have a healthy dose of trust in myself – I would say in this regard I am a 9 on a 10­level scale.

dan Brake Technical services director for the power generation division at Nextera energy Resources, florida, United States

Basis for progress In my view, any cooperation that is not based in trust can neither be effective nor efficient. If there is no trust, time and money are spent in monitoring the other partner. Time and money that could otherwise be spent on gaining a lead over others. Only with mutual trust is an open error culture conceivable. Honest communication must be possible as deviations from what was originally agreed are unavoidable in daily routine. Trust therefore excludes the possibility that an individual wishes to gain personal advantage. I trust other people in the business and private sphere because I don't want to invest any valuable time in monitoring the agreement made. I only work together with people I can't trust if external circumstances require me to.

Michael Schäfer R&D director at ersa GmbH Germany

32 | 33

Soplar's PET stretch­blow molding machines create plastic packaging with exceptional shapes and a crystal clear appearance – for example, for the cosmetics industry.

real.times 11 | 2016


Plastic Bottles:

A High-Tech Product When something quite simple requires a lot of know-how

Shower gel and shampoo, laundry detergent, ketchup and motor oil are packaged effectively in plastic packaging. If the ­bottles are empty, they are disposed of and at best reused as part of a ­recycling process. They have a short lifespan. However, the simpler and more efficient their use is, the more complex and demanding is their manufacture. This also places considerable demands on the automation technology.

34 | 35

Versatile: The extrusion blow molding plants supplied by Soplar process a wide range of plastics. These for example are completed for Soplar's customers for bottles with handles and multi-layer containers with up to six layers.

«Trust takes over control of the ­decision making in situations that are ­characterized by complexity, time pressure or the lack of information.» Niklas Luhmann Sociology professor at the University of Bielefeld

real.times 11 | 2016

Whilst we are surrounded with increas­ ingly more plastic in our daily life, mankind’s environmental awareness is increasing at the same time: It is the wish of mankind to reduce the consumption of energy and resources. At the same time, however, the consumer wants to have everything cheaper, and so there is tremendous pressure to cut the cost of packaging. Packaging material therefore always has to be improved, made cheaper and more eco-friendly at the same time: requirements which can only be achieved together with great effort. The requirements are demanding – not only for the packaging material ­itself, but also for those machines that ­produce it. Soplar sa, based in A ­ ltstätten, ­Switzerland, has specialized for over 30 years in the development, manu­ facturing and maintenance of extrusion blow molding machines and molds, as well as stretch blowing machines. World renowned bottling plants of food, ­cosmetics, household and laundry ­products, as well as oils and lubricants trust in the systems supplied by S ­ oplar. “Flexibility is certainly one of the major issues of the future,” said Roger Mahrle, CEO and head of technology at Soplar. “The machines have to be able to be refitted quicker and easier in order to effectively cover the greater variety of products with a wide range of basic materials, with several variants and quantities.” Ingenious technology Plastic packaging, such as shampoo ­bottles or water canisters, are manu­ factured with the extrusion blowing process. This shapes hollow objects from thermoplastic materials. In s­ imple terms, a plastic tube in a softened state is made into a shape, welded at the correct points when the mold is pressed together and then blown into shape. The tube thus takes on the shape of the mold. This process enables the production of a wide range of packaging types or technical components such as fuel tanks and ventilation ducts. “Our machines can also produce striking designs and implement advanced product features,” Roger M ­ ahrle explains. “Both bottles with handles as well as multi-layer containers with up to six layers can be produced on our machines without any problem.” Even if you think that the complexity of the packaging will be a critical issue in the future, Roger Mahrle doesn’t think

«It's nice to have a partner with whom you can discuss innovative ideas and then implement them quickly.» Reinhold Wüstner Head of the control engineering department at Soplar

like this: “We have certainly mastered this process. For whatever one wishes to ­focus on, the use of new and more environ­mentally friendly materials includ­ ing bio-based plastics is always possible.” The right mold The machine users, i.e. the customers of Soplar, determine the mold design, the material selection and the p ­ rocess. “We at Soplar therefore see our c­ hallenge in providing a mold with our machines that enables our customers to define and develop their process as easily as ­possible,” Roger Mahrle said. “If the machine operator has to set a­ bstract ­p arameters beforehand in order to manu­f acture the product, the end ­product itself and the machine define the necessary parameters. Meeting these challenges requires a very extensive amount of process know-how, which we have gathered over several years and which is one of our standout features.”

Durable machinery Although some product features are only required for a limited time and the technology is continually a­ dvancing, the p ­ roduction machines are used over ­s everal years. In order to meet the changing market requirements placed on ­p ackaging manufacturers, many addi­t ional functions and updates are carried out and also retrofits if neces­ sary. If some of our customers have ­s everal ­machines and buy a new one, they normally require the functions to be implemented on the old machines. This update must be ensured, even if auto­ mation components have to be upgraded as well,” explains Reinhold Wüstner, head of control engineering at Soplar. This requires a controller that can be adapted at any time, “but also the trust in one’s partner to be later willing and able to produce these components years later and stand by us in the upgrade of our customer’s old machine to the new

36 | 37

one,” Reinhold Wüstner adds. “Standard ­components with a high level of ­c apability are needed and a system that offers complete openness and thus optimally supports our development p ­ rocess.” All these are reasons why Soplar relies on Bachmann electronic controllers for its machinery. “We are buying here a solid basis that provides us with all the relevant functions,” Reinhold Wüstner explains. “This therefore allows us to concentrate on our core business and include our process know-how to produce an optimum overall system.” Added to this is of course the fact that there have been many technological changes in recent years: “Drives are more intelligent, new communication options are required – sometimes we are ahead of trends with our requirements. It’s then nice to have a partner with whom you can even discuss innovative ideas and then implement them quickly,” Reinhold Wüstner adds. Challenges from new developments Industry 4.0 or Industry 2025, as they call it in Switzerland, is a hot topic ­everywhere and also at Soplar. “The ­communication requirement will increase and also the use of sensors. This will for example provide better diagnostic options, automated processes and the early detection of wear,” Roger Mahrle explains. Nevertheless, Industry 4.0 sets clear restrictions in terms of diagnostics: “The causes of machine failures n ­ aturally have to be identified and downtimes reduced. However, I don’t think that the customers will so readily hand over large volumes of data to their suppliers. This mostly involves internal data and requires a trust-based relationship if any benefit is to be gained from it. That is why I think that this issue will take considerably more time, and every effort will also continue to be made to increase technical availability.” On the other hand, Roger Mahrle sees great potential in terms of increasing productivity through the standardization of interfaces and proto­ cols: “Today machines that process the individual process steps of a s­ equence are more or less controlled in isolation. Each one operates independently and communication between them tends to be rudimentary. It will therefore get interesting when the individual machines have to coordinate with each other when interconnected.”

«It will get ­really ­interesting when ­machines coordinate with each other in the network.» Roger Mahrle CEO and head of technology at Soplar

Challenges in new markets “Naturally, these kinds of solutions are available as complete systems from ­i ndividual vendors. However, these ­s ystems have the restriction that they do not necessarily provide the optimum solution for the particular ­a pplication,” Roger Mahrle mentions. With the ­introduction of the OPC UA ­communication standard, the initial way ahead has been prepared for larger ­controller manufacturers like Bachmann, and so the integration of individual machines in a machine network will be simpler.

However, a great deal of know-how in the operation of the plants is still required for demanding production processes. Particu­larly in expanding markets such as in Asia, it is difficult to train ­specialists and keep them in the company. “­O peration and networking must there­ fore be kept as simple as possible,” Roger Mahrle continues. “Only then is it ensured that machines or later the machine network can always operate reliably and productively.” The cost pressure and competition from Asian competitors in the global market are nevertheless high. “That is precisely why we concentrate on

real.times 11 | 2016

Soplar's perfectly coordinated development team do all they can to develop systems and plants that go beyond current requirements and take into account future issues.

the further development of our machines in order to also create a genuine differen­ tiation feature with simple operation and easy to implement networking,” Roger Mahrle gives a clear outline of the future. In summary, Soplar’s expectations of its ideal controller supplier are clear: “For me it must supply standards, and with them support our development processes and daily work. It must think ahead and ideally also introduce us to perhaps entirely new ideas through new technologies,” Roger Mahrle concludes.

Soplar sa was founded in Altstätten, Switzerland, in 1978. The company develops, produces and offers services for extrusion blow molding machines and molds, as well as stretch blowing machines. Over 1,000 plants have been installed worldwide in 35 countries. Around 150 people are employed in Altstätten.

38 | 39



rElIaBlE COMMunICaTIOn bluecom protocol – ideal for use in wind farms For the grid operator, a wind farm should behave like a single power station. The stable implementation of this kind of virtual power station requires fast, deterministic and fault­tolerant data exchange within the farm. The bluecom protocol was specially defined and developed for this kind of application. It provides the necessary throughput to enable the real­time exchange of large data volumes in short cycles between several nodes. It also enables the connection and disconnection of any wind turbine as required. For maximum reliability in the data connection, bluecom also allows various forms of redundant networking whilst still retaining real­time capability.

dIrECT EXChangE OPC UA client for M1 controller Intelligent sensors, which not only supply values but also receive parameter data, are increasingly being equipped with an OPC UA server interface. The new OPC UA client enables Bachmann controllers to be optimally prepared: The client can be installed on an M1 controller without any additional hardware and covers both the field and the control level.

In the field level it makes it possible to set the parameters of intelligent sensors during operation, in order to configure switch thresholds, response times or signal filters. At the same time it can receive the measured values and provide them for the PLC program without involving any additional programming effort for the user. At the control level,

i.e. up to systems for production data acquisition, the flow of signals is reversed and a single write command, for example, enables all the recorded production data of a workpiece to be transferred. This ensures consistency and the correct assignment of all data to the particular workpiece.

real.times 11 | 2016

daTa BECOMES KnOWlEdgE Fleet management reduces operating costs In its development work, Bachmann is focusing on automation solutions for optimizing the vertical data flow. The fleet management system (FMS) software module turns the data from the machine sensors and actuators into knowledge that can be used world­ wide. This enables condition­based maintenance to be carried out beyond the boundaries of plants and their owners – and without any additional effort. Machine availability can be then increased and unscheduled downtimes kept to a minimum, thus considerably reducing costs. For this, Bachmann's FMS is primarily based on data and standards that are already available today. Bachmann FMS increases the quality of the information to be obtained from the data by aggregating and analyzing it in a suitable form for specific target groups.

FMS Push FMSFMS Pushmodule FMS module Application Application

Cloud Cloud

FMS Portal FMS Portal

Stuttgart Stuttgart (D) (D)

Webspace Webspace atvise®atvise® webMI webMI User administration User administration

Boston Boston (USA) (USA)

Group administration Group administration

Plantadministration Plantadministration Wuxi (CN) Wuxi (CN)

Server and Server database and database

MOdErn TEMPEraTurE COnTrOl Versatile functions with the ‘ATeC’ software package

aTTraCTIVE OPEraTOr TErMInal OT1321 as VESA version The OT1321 with a VESA mount adds a powerful panel PC with a bracket design to Bachmann's HMI portfolio. The aluminum housing provides an attractive appear­ ance, and houses the 21.5 inch display with full HD resolution and capacitive multi­touch functionality. The tried and tested processors of the OT1300 product series ensure a powerful performance. As a complete solution together with atvise® SCADA, the operator terminals provide a fully­fledged visualization solution based on the latest web technologies.

ATeC (Adaptive Temperature Controller) is the name of the latest development from Bachmann. This is a temperature controller that is available as a software package for the M1 automation system. ATeC adjusts itself automatically to the characteristics of the controlled process, and thus operates adaptively. Besides the actual temperature control on machines, a number of other useful functions can be implemented with it as well. This therefore enables the monitoring of different criteria such as temperature limits, control deviations and temperature change. An individual delay time and response can be defined for each monitoring function. Furthermore, protection functions for all control systems and an intelligent power management function with current and power limitation are integrated. ATeC is oper­ ated in SolutionCenter and suitable C/C++ and IEC61131 libraries are available for application programming. The temperature controller is used for example for the tempering of molds or injection units in plastic and metal processing, for soldering baths in PCB assembly or for controlling thermodes.

40 | 41

CErTIfICaTIOn SuCCESS IEC 60870 Server rigorously tested by DNV GL

SlIMlInE EngInEErIng Useful tools in SolutionCenter

The IEC 60870 Server is a software solution that is installed directly on the Bachmann M1 controller. The already existing IEC 60870 server was upgraded to enable redundant communication. This allows power stations and wind farms to be monitored by several control centers distributed in the country. The prestigious DNV GL certification body subjected the entire software solution to rigorous testing over two days at the Bachmann branch in Silkeborg, Denmark. All test cases were completed with 100% success. The IEC 60870 server has thus been certified successfully.

Modern wind turbines consist of complex mechatronic systems which can only be implemented through the close collab­ oration of all the engineering sciences required for the process. This complexity is handled by breaking down the plant into logical function units, also known as components. The Component Manager from Bachmann electronic supports this process. This tool represents individual components as software modules in the M1 automation system. These can not only be created in the optimum program­ ming language for your task but also purchased and reused. This makes it possible to add new custom variants, different product versions and new functions without modifying the existing software. The engineering effort required is therefore reduced through this process.

rElIaBlE COnTrOl Current-regulated control of proportional valves The new PVA200 modules enable the direct and reliable current­ regulated control of proportional valves without an amplifier – irrespective of manufacturer and valve type. Depending on type, four to eight hydraulic or pneumatic valves can be connected. The relevant parameters are set in SolutionCenter or via web configurator. The settings can be saved as templates, thus simplifying maintenance operations. Thanks to their functional and typically robust design, they are versatile and ensure long term capability.

real.times 11 | 2016

dIagnOSTICS aT ThE PuSh Of a BuTTOn Portable Bachmann CMS for wind turbines In the USA a portable condition monitoring system (CMS) for wind turbines is causing a sensation. The compact and robust device has 18 channels for vibration measurement, and provides reliable information about the state of the turbine's drive train. This enables any faults to be identified quickly and any unnecessary maintenance to be avoided. The system includes a laptop that collects and saves the data for different operating areas and over an adjustable time period. Bachmann experts analyze and assess the data. Customers then receive a clear status report and a recommendation for further action. The portable CMS collects all the data at the push of a button without any other accessories needed. This therefore enables small wind farms to also enjoy the benefits of a reliable CMS.

nO PrOBlEM WITh grId COdES With the latest GM232 generation The GMP 232 is a PLC­integrated grid measurement and monitoring module for electrical three­phase networks. It fits seamlessly in the tried and tested M1 controller environment. The latest generation offers additional calculation processes, high precision frequency measuring and enhanced protection func­ tions. As a PLC­integrated state­of­the­art solution for grid measurement, protection and high supply quality, it provides the basis for reliably observing the grid codes, which are increasingly becoming more stringent.

42 | 43



COnTrOllEd TEnSIOn Cable laying for offshore wind turbines In the middle of 2014, Van Oord, a solution supplier for dredging coastal areas and building plants for offshore power generation, launched the cable laying vessel ‘Nexus’. This multi­functional vessel is used for installing electrical cables for offshore wind farms. Difficult environmental factors – such as high

waves – turn this task into a major challenge. An innovative winding system from Pliant was used to prevent damage to the electricity cable. The M1 automation system from Bachmann ensures that the cable laying is reliable.

real.times 11 | 2016

Impressive: One of the three storage pumps at the Ferrera station.

EVERYTHING IN VIEW Clear visualization for air handling units The special high-performance heat exchangers for the air handling units of the Swiss company Konvekta guarantee the highest recovery rates and thus a massive reduction in CO2. Ventilation heat loss still represents a considerable proportion of the overall heat loss in a building. With the new ‘Eiger’ energy recovery controller generation, customers are provided at a glance with a clear visualization, the so-called Konvekta eye, and a view of the most important plant functions and processes, as well as the recovery rate. The 15.5” wide screen web panel with multi-touch operation from Bachmann is predestined for this application.

ELECTRICITY FROM FOUR STATIONS Impressive control technology project for hydropower stations Kraftwerke Hinterrhein AG (KHR) is a company that operates the largest combination of hydropower stations in the Swiss canton of Graubünden with four power stations in Ferrera, Bärenburg, Sils and Thusis. For 50 years KHR has been producing around 1,400 GWh of environmentally friendly electricity a year. The control equipment will be replaced by solutions from the Swiss company Rittmeyer as part of a general upgrade to the plants over six years. This is based on the M1 automation system from Bachmann.

Barrage system of the Lago di Lei seasonal reservoir

Concrete Length Capacity

840,000 m³ 690 m 197 million m³

44 | 45

High CPU Performance ­Required Precise application in a challenging environment Thermo Scientific Messtechnik GmbH is headquartered in Erlangen, Germany, and supplies system solutions for the coating weight gauging of flat sheet or web ­products in the metal, plastic and the rubber industry. Over 15,000 of its systems are installed worldwide, enabling contactless and non-destructive online measuring and control during ongoing production. The challenges placed on the automation are enormous, and require up to 100,000 measured values to be processed per second and safety-relevant standards to be fulfilled at the same time. Bachmann's M1 automation system with its integrated safety concept is perfectly suited for this task.

The Factor for ­Success Bachmann M1 automation as the core of wind turbines The Guodian United Power Technology Company Ltd (GUP) is headquartered in China and is one of the largest wind ­t urbine manufacturers in the world. Its 2 MW, 3 MW and 6 MW plants are equipped with the M1 automation system from Bachmann. The company currently has the largest installed c­ apacity of 2 MW wind turbines in China. The company intends to expand the offshore business in order to further grow the company. The ColdClimate versions of the M1 ­modules are indispensable here since they also operate reliably in extreme climatic ­conditions.

real.times 11 | 2016

PrOfITaBlE COndITIOn MOnITOrIng Wind turbines in a challenging environment CSR Wind Power has been using the Bachmann M1 automation system for several years as the controller for its 2 MW turbine. More than 100 wind turbines are currently being delivered to the Huarun Power Group in Hubei province (China) and commissioned. Initially 28 of these systems are being fitted with the Bachmann CMS condition monitoring system. CSR's exten­ sive know­how combined with the experience drawn from this project are being used as the basis for developing future CMS systems that are optimally adapted to the diverse environ­ mental conditions in China.

46 | 47

EVErYThIng undEr COnTrOl – EVEn In STrOng WInd Safe installation of offshore wind turbines with Boom Lock© Boom Lock is a mechatronic system that enables offshore wind turbines to be installed faster and more safely even in strong winds. In a test run, the blade of a 6 MW turbine could be held stably in the wind – at a wind speed of 15 m/s with gusts up to 20 m/s. Since then an offshore project was successfully completed in which fifteen 3.3 MW turbines were installed. Boom Lock is controlled with a Bachmann M1.

real.times 11 | 2016

a fOundaTIOn YOu Can BuIld On Ships fitted with an automation system containing Bachmann hardware Ullstein specializes in the construction and development of special ships for research and for offshore use. The ULSTEIN IAS® automation system enables the control and monitoring of machines and drives, ship's power, alarm systems, power supply and also management. However, it can also be used for other function­critical systems. The ULSTEIN IAS® is based on the M1 controller and has a decentralized configuration, so that any automation tasks are handled in autonomously operating subsystems. In this way the functionality of the plant is retained even in the event of a fault.

‘gaMMa-BuSTEr’ Nuclear-free density and concentration measuring The DENS­ITOMETER from ITS (Industrial Tomography Systems) is a system for measuring the concentration of solids and the density of liquids and slurries in pipes. Unlike conventional densito­ meters, it operates without a nuclear energy source and so it is also known as the ‘Gamma­Buster’. Based on electrical resistance tomography, the measuring

system reliably measures data, irrespective of flow and material concen­ tration. The concentration information is provided as a 4­20 mA signal. The device is designed as a tubular sensor and comes in a robust housing together with a Bachmann industrial PC. The system also reliably supplies real­time data irrespective of flow regime and

material concentration, even in extreme conditions, such as with 1.2 m pipe diameters or slurry conveying rates of over 30,000 tons per hour. Once installed, the DENS­ITOMETER requires no further maintenance or specially trained personnel and offers an environmentally friendly and inexpensive alternative to conventional devices.

48 | 49

ÂŤThe technology adventure is much more than a pleasant cooperation.

It is the spirit of togetherness based on trust, from which fascinating technical solutions are produced that push back frontiers – for everyone's benefit. gerhard Bachmann founder of Bachmann electronic

real.times 11 | 2016

50 | 51

Real.times 11 2016 EN  
Real.times 11 2016 EN