Creating reports based on S7 datablock action

 I want to create reports based on the error messages from our machines.

The programming groups all the errors into datablock bits which are then transferred as tags in the WinCC.

I want to connect up a PC that will also monitor these Datablocks on each of the PLC's and will log every time one of the error bits becomes true, logging it with the time and date. Then, I want this log saving and possibly even automatically emailed to people who need to know.

Also, with this collated data, I want it to track the number of instances for each error so that I can find out what the top 5 errors are per machine, per month. This will give us some activities to focus on for the coming month in order to improve machine reliability and also to track trends. I've attached a diagram to try and show what I am after a little clearer.

I'm not sure where to start with this. Whats the best way to connect the PLC's to the Data recording PC? Whats the best way to record the changes in the DB? Whats the best software solution to create the log? Whats the best software solution to query the data each month?

Any help would be much appreciated....

Mark Lee

Hello,

probably little bit complex question  for first will be better post your programming experience on PC side, we don't know nothing about this, also what programming language/Studio you're using on PC and PLC (Step7 v5.x or TIA, also what WinCC version). In basic my view it can be probably achieved via some OPC system (you can select one) to collect data from PLCs, but with this solution it can be payed attention to connection interface, PC must connect to PLCs via this, so what kind of connection do you want use due your PLC interfaces? This can be basic start for collect infos and then we can go next. Simply I think you cant disturb PLCs with some kind of user defined serial/ethernet communication from PC application, OPC can be best solution in this case I think. Then you can work with your collected data from PLCs with your PC application as you need - read/write to PLC, log data to SQL DB, create/print reports, ... This is my quick look to this situation, other can also post better solution for you.

Hi Duris

Apologies, I've only just seen your reply. I don't use this forum much as I find it hard to see when I get replies.

Still working on this project but this is the way forward that I've worked out.

So, the SQL server was set up on a laptop PC using Microsoft SQL manager 2014.

In order to accept PLC data and turn it into SQL commands, I'm using a visual basic program called AdvancedHMI. Some custom code donated from the developer and from VB forums has helped get this side up and running.

I use mostly 300/400 Siemens CPU's in the factory and some Omron. So I needed a communications protocol to use... The AdvancedHMI has built in Modbus comms drivers so that was decided to be used. As we don't have licences for Modbus communications on any of our CPU's. But I do have a spare S1212C CPU which has modbus ability built in.

So, the Siemens CPU's will all be on a S7 network to the S1212C CPU, which will act as an interface to the Data recorder PC. 

All working on a test rig and implementing on a single machine to test worthiness.

I think that you are trying to design a analys Tool. Try to se the Win CC add on:

http://w3.siemens.com/mcms/human-machine-interface/en/visualization-software/scada/wincc-addons/pm-analyze/Pages/Default.aspx

BR. Sven