ROCHE DIAGNOSTICS GMBHMANNHEIM

Case Study

Roche Diagnostics is the world‘s „Number 1“ in the diagnos- tics business. From the central logistics centre in Mannheim, Roche offices in 170 countries and customers in Europe are supplied with reagents, instruments and spare parts. Every day, over 4,000 shipments leave the Mannheim site. An expansion of the logistics centre is intended to cover

growth in the coming years. Aberle GmbH was awarded the contract for the supply of the complete control system for safety and materials handling as subcontractor. The required process control system was supplied by Aberle Software GmbH. The project was carried out within only twelve months` time.

PROJECT / CUSTOMER‘S REQUIREMENTSPROCESS CONTROL SYSTEM WITH ON-SCREEN OPERATION, CONTROL SYSTEM FOR PALLET CONVEYORS, CONTAINER HANDLING SYSTEM AND SAFETY SYSTEMS

Work stations for adding documents Transverse shuttle

Incoming goods Process Control System mask, state and occupancy of SRM in the high bay warehouse

Case Study ROCHE DIAGNOSTICS GMBH

BENEFITS / SPECIAL FEATURESAutomation of the system implemented by Aberle GmbH is based on an integrated overall concept which leads to rapid apprehension and acceptance of the system by plant operators and maintenance

personnel. The comprehensive solution implemented allows Roche to process a much higher number of or-ders per day. Thus at Roche, the ever-growing market has already been taken into account.

Control Configuration - Safety Technology

Solution

Due to the complexity of the system, the 2,000 drive mechanisms of the pallet conveyor system are equipped with ASI compatible Movimot remote controls. The inte-grated manual control allows operation of three different controls using the same device. Simple, easy to under-stand dialogues have been implemented on the MP170 portable panels. The 2,000 conveyor drives are controlled conventionally via decentralized control cabinets situated all over the system.The 400 emergency stop buttons, maintenance flaps and protective doors throughout the plant are integrated with the aid of 98 I/O modules via the safety bus.

Integrated components

Below the order processing system, the delivered process control system coordinates and controls the material flow of the connected conveyor and machine control systems.A complex on-screen visualization system is part of the process control system and is installed on approximately 50 PCS clients. The underlying controls employ modern S7 automation technology and Profibus-DP/ASI Bus.Manual control of the pallet conveyor system uses the latest generation of Siemens MP170 panels. Scanning of barcodes is done with 250 Sick CLV430/450 scanners, connected serially to the CLX200 network controller. Because of the physical size of the plant and the complex safety requirements, four Pilz PSS 3006-ETH safety controls are used with safety bus interface.

Case Study ROCHE DIAGNOSTICS GMBH

Industry Pharmaceuticals

Load units wooden pallets, cartons in 5 sizes, plastic totes, trays

On-screen monitoring system Aberle visualization

Process control system 1 PCS-Server IBM RS 6000 1 PCS-Server IBM RS 6000/ Hot-standby 50 PCS-clients

Data Concentrator 1 Siemens S7-400 414-3 DP for Emergency Stop messages

Automation technology 10 Siemens S7-400 414-3 DP/ 416-3 DP 7 Siemens mobile panel MP170

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Aberle GmbHDaimlerstraße 4074211 Leingarten · GermanyPhone +49 7131 9059-0Fax +49 7131 9059-59www.aberle-automation.cominfo@aberle-automation.com

TECHNICAL DATA