Semiconductor technology for high availability

Wernsing Feinkost processes around 450,000 tons of potatoes annually, making high plant availability critical. To minimize downtime caused by short circuits, Wernsing and automation partner Rilo use the SIMATIC ET 200SP e-Starter, delivering ultra-fast protection and high short-circuit resistance.

Challenge: High availability in areas prone to short circuits

In the highly automated production environment at Wernsing Feinkost GmbH, large quantities of potatoes are processed into a wide variety of delicatessen products. Numerous conveyor systems transport raw materials and goods throughout the entire production line. Even malfunctions in individual components can disrupt the production flow of entire lines and cause unplanned downtime. Short circuits can also lead to such interruptions. What is crucial here is not only reliable protection of the device and the application, but also rapid restart to keep unplanned downtime to a minimum. If the motor starter must be replaced in the event of a short circuit, this can result in both costly time and service expenses. A solution was sought for this problem that offers reliable short-circuit protection while simultaneously reducing the time and cost involved in the event of a malfunction.

Semiconductor technology in practice

Together with Wernsing, Rilo Automatisierungstechnik GmbH & Co. KG opted for the semiconductor technology of the SIMATIC ET 200SP e-Starter. The focus was on a motor starter solution that offers high short-circuit resistance, allowing the starters to be put back into operation immediately after troubleshooting. The integrated Smart Start feature is used additionally to ensure a smooth start under load. At the same time, the solution needed to integrate seamlessly into the SIMATIC ET 200SP system and the TIA Portal, offer comprehensive diagnostic capabilities, and display operating statuses directly on the device. A compact design and an integrated reversing function for clockwise and counterclockwise rotation were also key practical requirements.

Siemens has developed a solution that combines key functions – such as short-circuit protection and Smart Start – in a single, compact unit. The innovative semiconductor technology in the e-Starter was a perfect fit for our system.

Guido Quittek, Managing Director, Rilo Automatisierungstechnik GmbH & Co. KG

Our solution: The fully electronic motor starter

The SIMATIC ET 200SP e-Starter uses modern semiconductor technology to switch and protect motors. Silicon carbide MOSFETs are controlled by high-performance microcontrollers and ultra-fast power semiconductors, enabling fully electronic short-circuit protection. The e-Starter can detect and shut down short circuits in less than 5 microseconds – nearly a thousand times faster than previous switches. At the same time, the technology provides the foundation for the Smart Start function, which enables phase-optimized motor startup. This significantly reduces inrush currents and minimizes associated torque surges. This is a key advantage for Wernsing’s production. During palletizing, products are transported on pallets in a free-standing, unwrapped state. A gentle start-up of the conveyor belts prevents the products from slipping or tipping over. Even on heavily loaded potato conveyor belts, Smart Start reduces the starting current and thus protects the mechanical components.

System integration and analysis capabilities

Seamless integration with the SIMATIC ET 200SP peripheral system and the TIA Portal ensures that the data collected by the starter is transferred directly to the controller and from there to the TIA Portal. The fully electronic starter can be configured, parameterized, and commissioned directly in the TIA Portal using Step 7. This integration also enables detailed analysis of operating and diagnostic data – such as currents, voltages, operating hours, and other measured values – which facilitates condition monitoring and predictive maintenance. The result is a motor starter solution that is precisely tailored to the requirements of Wernsing’s modern production environment.

Ultra-fast short-circuit protection

Semiconductor technology enables the starter to detect short circuits within microseconds and instantly interrupt current flow. After the fault is cleared, the e-Starter can be restarted at the push of a button.

Smart Start for a smooth motor start

Smart Start reduces inrush current and starting torque. This enables a controlled startup of conveyor systems. At Wernsing, this can reduce the load on the conveyor system and prevent jerky movements of the conveyed material.

System integration and detailed diagnostics

Full integration with the TIA Portal provides access to detailed measurement, operating, and diagnostic data. This allows faults to be isolated more quickly and system status to be assessed transparently.

In addition to the overview of various measuring and operating data in the TIA Portal, we can view the most important information directly on the device via status LEDs. By reading error codes directly on the device and in the TIA Portal, we are able to reduce downtime caused by short circuits by up to 60%.

Stefan Niehe, Team Leader Electrical Engineering , Wernsing Feinkost GmbH

The smart way to increase system availability

The semiconductor technology used in the SIMATIC ET 200SP e-Starter ensures high short-circuit resistance and detects faults within a few microseconds. This fast response time forms the basis for high system availability and reliable production operations. In addition to intelligent maintenance, fast restart, and smooth motor starts, the SIMATIC ET 200SP e-Starter offers a wide range of other benefits in daily operation. Three of these are of particular note:

Less downtime, more uptime

The e-Starter protects itself in case of short circuits and can be quickly reset and turned on once the fault is cleared. By eliminating equipment replacement and enabling rapid troubleshooting, it cuts downtime by up to 60%.

Gentle operations of conveyor systems

The integrated Smart Start significantly reduces inrush current and torque, thereby enabling a more controlled motor start. This can reduce mechanical stress and protect sensitive materials from jerky movements.

Full transparency through smart diagnostic functions

Comprehensive operational and diagnostic data is available in the TIA Portal for in-depth analysis. This data not only enables detailed fault analysis but also supports intelligent condition monitoring and predictive maintenance.

Rilo Automatisierungstechnik GmbH & Co. KG: Practical and innovative

Rilo Automatisierungstechnik has been providing solutions for industrial and process automation for over 20 years and is primarily active in the food and agricultural sectors. As a long-standing partner of Wernsing Feinkost GmbH, the company supports the planning, implementation, and further development of its automation solutions. Thanks to this close collaboration, Rilo has a detailed understanding of Wernsing Feinkost GmbH’s production processes and requirements. In a joint project with Siemens, Rilo contributed its practical experience to the development of the SIMATIC ET 200SP e-Starter. The focus was particularly on easy integration into existing systems, high short-circuit resistance, and efficient operation.

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Where potatoes become a delicious variety of products: Wernsing Feinkost GmbH

Wernsing Feinkost GmbH is a food manufacturer with highly automated production processes that specializes in processing potatoes into a variety of delicatessen products. Numerous conveyor systems transport raw materials and products through the production line – from the receipt and storage of large quantities of potatoes through processing to palletizing. Heavy loads, mechanical stress, and intensive cleaning processes place special demands on the technology used. Reliable motor controls, trouble-free operation, and rapid fault diagnosis are crucial for high system availability. In a joint project with Siemens and Rilo, Wernsing contributed its extensive practical experience from production to the development process.

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