Title:

Condition Based Monitoring of Lindt Bar Line

The objective of this project was to install sensors on components on the Lindt Bar Line that have critical importance to the performance of the line and the quality of the product. The installation of eighty three sensors, fifteen IO Link Masters, electrical cabinet components, and cabling was overseen during a plant shutdown. In Siemens TIA Portal, the Condition Based Monitoring, CBM, PLC was programmed. Representations of the cabinet components and all IO Link Masters were added in the Network Devices tab where they were appropriately connected. A tag was made for each sensor using the master connection charts and user manuals as resources. Also by using the user manuals, types were constructed. One was made for each kind of sensor, for a total of seven types. Fifteen data blocks were made, one per each master, where each line corresponded to a port. Function calls were where the most difficult programming was done due to it being in structured text. This is where operations are done to take the input process data and convert it into the output parameters. Lastly, in the Siemens TIA Portal software, the Main OB1 was configured that brought all of the previous items together. Once the programming was complete, it was downloaded onto the CBM PLC. Measurements from the sensors could be seen in the data blocks. The data block numbers and the offsets were used to make tags in Ignition for all outputs so the data could be collected and analyzed. High level alarms were set for each output with a notification pathway to alert maintenance staff of any issues. Values were collected in Ignition and any irregular outputs were flagged for troubleshooting. It was found that there were cases of improper wiring and programming bugs which were remedied.

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