Retrofit for Handheld Control Units
The ROTH Operator Panel (ROP) is a handheld control device designed to retrofit machines based on Sinumerik 810 / 840D Powerline controllers. The key feature: The ROP is a direct replacement for the PHG handheld programmer—which is no longer available—as well as the HT6 from Siemens. It is a modern alternative that offers guaranteed spare parts availability and simplified operation—not least thanks to the integrated ACCON-AGLink communication software from DELTA LOGIC.
It’s literally old news: One day, a manufacturer stops producing a certain product simply because there’s a successor that’s better, faster, and more in line with the times. Even the success story of an icon like the VW Beetle eventually came to an end—as legendary as the “Economic Miracle” car once was. Viewed objectively, this isn’t a tragedy, but simply the way things go—and you can stay calm as long as there really is a suitable replacement. But what if that isn’t the case? Then things can get difficult and expensive.
Siemens discontinued its Programmable Handheld Device (PHG) quite some time ago—it is no longer manufactured and is no longer available as new-in-box stock. However, the machines that have been operated with it so far are far from obsolete. Even though they may well date back to the last millennium, they are fully functional, productive, and urgently needed. However, as soon as the handheld control unit breaks down, companies face the dilemma of how to find a replacement, because without this device, the vast majority of machines can no longer be operated.
One possible solution would be a complete control system upgrade, including a control panel package, which would entail not only a very large investment but also extremely long delivery times. However, most machines must be available at all times without unplanned downtime—after all, you can’t keep customers waiting. In contrast, retrofitting with the ROTH Operator Panel (ROP) from ROTH Steuerungstechnik is a much more elegant and significantly more cost-effective solution.
Retrofitting Offers Valuable Benefits
Automation and handling systems, as well as machine tools based on Sinumerik 810/840D Powerline controls, can be equipped with the new ROP operator panel and resumed operation in the usual manner with less than three hours of downtime. At first glance, the brilliant and sharp 10-inch color display catches the eye—a noticeable improvement over the classic Siemens model.
The display and operation are identical to those of the original SIEMENS devices—the transition is seamless, and no training is required for production staff. The rotary switch for controlling the systems’ feed rate offers enhanced convenience, as is typical of the latest generation of control devices.
But retrofitting with the ROP offers further, far more significant advantages, explains Julian Frank, sales engineer at ROTH: “With the ROP, we offer companies a gateway into the world of Industry 4.0 by enabling even older equipment to be connected to existing MDE/BDE systems. If you think this through, it even opens up the possibility of purchasing used machines instead of expensive new ones—machines that, thanks to the retrofit and in combination with the ROP, have a significantly extended service life.”
As a plug-and-play solution, the ROP is designed to allow for quick replacement and to utilize existing connections and even mounting holes that were compatible with the PHG/HT6 units. ROTH promises customers a downtime of less than three hours during the retrofit. Since all existing functions are retained 100 percent, the machine upgraded with the ROP can resume operation immediately. “The ROP kit includes all the conversion materials,” says Julian Frank, “and everything remains unchanged on the control cabinet and other sensitive components, including machine safety and CE compliance.”
Among the additional advanced features offered by the ROP is the rapid availability of machine data, which can be retrieved via an Ethernet interface. Other features include automatic data backup, the option for remote maintenance, and, last but not least, customer-specific customizations—ranging from the integration of the customer’s own company logo to individual machine functions and the transmission of data to the customer’s higher-level systems.
Intergenerational Communication
A key element for the ROP and its extensive range of functions is the integration of DELTA LOGIC’s ACCON-AGLink software. On the hardware side, this is achieved via the ACCON-NetLink-PRO compact programming adapter, which enables communication between a PC and S7 controllers. With this adapter, the ROP can connect even older machines with interfaces such as the MPI bus to new-generation systems and controllers via PROFIBUS or to the IPC Ethernet environment.
ACCON-AGLink, the tried-and-true, high-performance library for industrial communication, has been used for many years in numerous applications and across a wide variety of industries. Its greatest strength lies in its ability to support all controller types in Siemens S7 environments and to enable data exchange regardless of programming languages and operating systems—all at an outstanding speed. The specialists at DELTA LOGIC are known, not least, for always adapting their solutions to new requirements—as is the case with the innovative ROP from ROTH Steuerungstechnik.
DELTA LOGIC also finds the right solutions for individual customer needs: For example, the SINUMERIK add-on from ACCON-AGLINK was developed at the request of another customer. This enables the reading of all variables from Siemens’ very comprehensive list manual. In addition, online access to user-defined variables, known as GUDs, has been implemented. This functionality benefits all customers who wish to access Siemens’ SINUMERIK machine tool controls. These functions are also used in other DELTA LOGIC products. For example, since the update to version 1.1, the ACCON OPC Server UA has also supported access to SINUMERIK CNC controls.
A Strong Team
ROTH Steuerungstechnik relies on DELTA LOGIC’s products and expertise in many other areas as well. These include large-scale projects such as the development of control system software for rail transportation or warehouse management, as well as more streamlined applications designed for just one or two specific tasks—typically C#-based software that is often tailored to very specific customer requirements. Julian Frank: “First and foremost, we value DELTA LOGIC’s Swabian-made products because they simply work! That may sound trivial, but it’s fundamentally important in our field. And if we do ever need help, we get it—quickly and with exceptional expertise. Our customers also provide this feedback: trouble-free operation, high performance, and, last but not least, innovative enhancements. DELTA LOGIC consistently introduces new features that ensure we always stay at the cutting edge of automation technology.”
The two companies have been working together for several years now, whenever opportunities arise. “ROTH is a good customer of ours; we’ve been supplying them with our products since 2002,” said Rainer Hönle, CEO of DELTA LOGIC. “ROTH has consistently developed outstanding solutions for its market, in which our ACCON-AGLink software can fully demonstrate its strengths.” In 2019, DELTA LOGIC gained access to SINUMERIK ONE through ROTH, enabling it to thoroughly test several functions for the new generation of controllers. “Our collaboration on the innovative ROP will certainly not be our last joint project,” Rainer Hönle is certain.
Retrofit: An Attractive and Cost-Effective Alternative to Purchasing New Equipment
Siemens’ decision to stop manufacturing handheld devices for Sinumerik didn’t come completely out of the blue, however; the industry has been aware of it for years, as Julian Frank also knows. But now the situation may be getting serious: “Times have simply changed,” says the sales engineer from ROTH. “Due to changes in the market, many companies are forced to continue operating their existing equipment productively and economically for a few more years.” In this regard, the ROP offers them the planning certainty that replacements will always be available for defective and discontinued Siemens handheld devices—and for a long time to come. This includes a warranty and comprehensive customer support. In this way, the ROP gives many companies the opportunity to save—in some cases—even several million euros through retrofitting.
Julian Frank of ROTH Steuerungstechnik is convinced of the ROP’s success: “We have now delivered numerous units to customers; the ROP is operating successfully and has proven itself in practice. We are confident that the consistently strong market for the ROP will continue to develop positively in the future.”
Of course, time doesn’t stand still at DELTA LOGIC either. It goes without saying that proven, high-performance products such as the ACCON-AGLink communication library are continuously improved and further developed so that they can keep pace with technological advancements—or even set the new standard themselves. The next update, featuring new capabilities, is already available: In the current version 6.0, Accon-AGLink now offers the ability to securely exchange data via SecurePG/PC and HMI communication. The Sinumerik One and Create MyVirtualMachine machine tool controls can now also be addressed directly. A new module is also available with the Sinumerik Add-On.
Hönle, B: Retrofit for Handheld Control Units, in: etz, 6/2023, June 6, 2023, p. 10ff, https://emagazin.etz.de/de/profiles/12354bdf8065/editions/c3266fd8cd52bb2af624/pages/page/6
