Integration of QB Modules with Siemens PCS 7
Industry
Industrial Automation / Life Sciences / Pharmaceutical Manufacturing
Scope
Hardware and Software integration
Timeframe
1 month
-
1
IT/OT Engineer
-
2
Project phases
01
CLIENT
Siemens – a global leader in technology, industrial automation, and digitalization. The company provides advanced solutions for the manufacturing and process industries, including its process control system, Siemens PCS 7. As a pioneer in implementing Industry 4.0 standards, Siemens develops ecosystems that support the flexibility and interoperability of OT systems based on standards such as MTP (Module Type Package).
02
BUSINESS NEED
The primary objective was to validate and implement modular production standards within the client's innovation centers and "Living Lab" test facilities. The client required the integration of modular hardware units (QB modules) into the Siemens PCS 7 Distributed Control System (DCS) to verify the interoperability of the MTP standard. The solution was intended to enable a "plug-and-produce" workflow, reducing manual configuration efforts and simplifying the scaling of automated process systems.
03
CHALLENGE
To help our client achieve its goals, we overcome the following challenges:
-
MTP Compatibility
Generating and validating MTP/AML files that could be successfully imported into the client’s PCS 7 / Open OS environment. -
Protocol Alignment
Configuring OPC UA communication to match the specific requirements of WinCC/PCS 7. -
Standard Evolution
Overcoming limitations in native MTP support within existing systems, specifically regarding advanced services and process values. -
Adaptive Integration
Defining flexible integration scenarios ranging from simple manual control to complex, automated control loops.
04
SOLUTION
We acted as both a hardware provider and a technology partner, delivering a fully validated integration path for modular units within a DCS framework.
- MTP Implementation & Validation Developed and refined MTP files using internal generators and industry-standard tools (Simatic MTP Creator), ensuring successful recognition of units as MTP Process Equipment Assemblies (PEAs).
- Dual-Tier Integration Framework Established two distinct integration levels—a "Minimal" variant for rapid manual control and a "Full" variant for advanced process orchestration and extended logic.
- Simulation Environment Created a virtualized environment (VMware + PCS 7/WinCC) to demonstrate HMI interfaces and operator workflows before physical deployment.
Working with Siemens to bring our QB modules into the PCS 7 environment really showed what the MTP standard can do in practice. We didn't just want to connect hardware; we wanted to prove that 'plug-and-produce' actually works in a complex DCS setup. By mapping out clear integration levels and testing everything in a virtual sandbox first, we’ve created a solid roadmap for any legacy system to adopt modularity without the usual technical headaches.
Karol Doroszewski
Delivery Executive
Technology used
05
OUTCOME
The project successfully demonstrated that QB modules are "MTP-ready" for enterprise-level systems environments, providing a real-world playground for innovation in the client’s "Living Lab.
- Successful devices Import Confirmed 100% compatibility for importing PEA (Process Equipment Assembly) interfaces into the client’s DCS, ensuring reliable device recognition.
- Reduced Engineering Effort Established a standardized integration process that minimizes the need for manual coding in the DCS for each new device.
- Accelerated Knowledge Transfer The delivery of high-quality video tutorials and live demonstrators allowed the client's team to independently scale the solution.
- Future-Proof Roadmap Identified clear "game changers" for expanding MTP services and alarm management, paving the way for full-scale production rollouts.
06
IMPLEMENTED SOLUTION
-
Modular Units Readiness
Configured Cube Pumps, Sensors, and Multiscales as independent PEAs with native OPC UA servers. -
Custom MTP Engineering
Conducted iterative manual corrections and tool-based validations to ensure the MTP files met the specific structural needs of the client's DCS version. -
Living Lab Deployment
Shipped physical units equipped with Power over Ethernet (PoE) and Remote Diagnostic Suitcases (RDS) to ensure 24/7 availability and remote support for the client's engineers. -
Functional Scope Definition
Detailed requirements for HMI visualization, process signals, and alarm handling, aligning the technical output with the client’s operational standards.
-
1
IT/OT Engineer
-
2
Project phases