Ciros Advanced Mechatronics Manual 1

®

CIROS Advanced Mechatronics Manual

572761 EN 01/2010

Order No.: Status: Authors:

572761 01/2010 Christine Löffler

Graphics: Layout:

Doris Schwarzenberger 01/2010, Beatrice Huber, Julia Saßenscheidt

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, 2006-2010 Internet: www.festo-didactic.com E-Mail: [email protected] The copying, distribution and utilisation of this document as well as the communication of its contents to others without express authorisation is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration.

Contents

1.

What will you learn from the manual? ____________________ 5

2. 2.1

This is how you install CIROS Advanced Mechatronics _____ 8 User-specific installation of default sample systems

®

and S7 programs used ________________________________ 8 3. 3.1 3.2 3.3

The CIROS® Advanced Mechatronics system _____________ 11 Summary of CIROS® Advanced Mechatronics _____________ 11 A distributed system in CIROS® Advanced Mechatronics ____ 15 Communication in distributed systems __________________ 17

3.4 3.5

The preassembled station models in CIROS® Advanced Mechatronics _______________________ 19 Controlling a station with internal PLC __________________ 27

3.6 3.7 3.8

Controlling a station with external PLC __________________ 28 Functions for setting faults in a system __________________ 30 Functions for analysing a system ______________________ 31

3.9

Directory and file structure of CIROS® Advanced Mechatronics _______________________ 33

4. 4.1

Main control functions of CIROS® Advanced Mechatronics __ 38 Creating a new MPS® Standard system from preassembled station models _____________________ 38

4.2

Creating an MPS® 500-FMS system from preassembled station models _____________________ 58 Modifying an existing system _________________________ 78

4.3 4.4 4.5 4.6 4.7

Creating and monitoring communications links in a system _______________ ________________ _________ 93 Simulating a system ________________________________ 120 Operating and monitoring a system ___________________ 124 Changing the view of a system _______________________ 145

4.8 4.9 4.10 4.11

The Inputs and Outputs windows _____________________ 149 The Manual Operation window _______________________ 157 Controlling a system using the internal S7 PLC __________ 183 Controlling a system station using the external Soft PLC S7-PLCSIM ______________________ 199

© Festo Didactic GmbH & Co. KG  572761

3

Contents

4.12

Controlling a station of the system using the external Soft PLC CoDeSys SP PLCWinNT ____________ 215

4.13 4.14

Controlling a station of the system using an external PLC __ 241 Setting faults in a system ____________________________ 259

4.15 4.16

Eliminating faults in a system ________________________ 267 Logging error elimination ____________________________ 272

5. 5.1

These training contents can be taught using CIROS® Advanced Mechatronics ______________________ 274 Training contents and training aims ___________________ 274

5.2 5.3 5.4

Target group ______________________________________ 277 Prior knowledge ___________________________________ 277 Example: Allocation of training aims to syllabi ___________ 278

5.5 5.6

The training concept of CIROS® Ad vanced Mechatronics ___ 284 Training scenarios for CIROS® Advanced Mechatronics ____ 286

6.

This is how you create and operate a distributed system in CIROS® Advanced Mechatronics ______________ 289 Training aims _____________________________________ 289 Support via CIROS® Advanced Mechatronics ____________ 290 Example: Configuration of a distributed system from MPS® Standard stations and simulating production ______ 290

6.1 6.2 6.3

4

7.

This is how you analyse information flow in a distributed system________________ ________________ 318

7.1 7.2 7.3 7.4

Training aims _____________________________________ 319 Methods _______________ ________________ __________ 319 Support via CIROS® Advanced Mechatronics ____________ 321 Example: Analysing information flow in a distributed MPS® Standard system __________________ 321


1. What will you learn from the manual?

What is CIROS® Advanced

CIROS® Advanced Mechatronics is an application from the CIROS ®

Mechatronics?

Automation Suite. ®

CIROS Advanced Mechatronics is a PC based graphic 3D simulation system for distributed automation systems. These systems consist of different, internetworked, intelligent stations. The distributed systems represent automation processes of varying complexity. In the documentation and software, these systems are also referred to as process models or workcells. CIROS® Advanced Mechatronics is a tool whereby you define an automation process and configure the corresponding system for the predefined stations, familiarise yourself with the mode of operation of a system, familiarise yourself with and plan the communication between the networked stations of a distributed system, practise PLC programming and testing of PLC programs with the help of systems, carry out systematic fault finding on a system. The individual contents can be extended in complexity depending on the trainees’ prior knowledge. The simulated systems are also available as actual systems. With these you can successfully apply and consolidate the knowledge gained on the virtual automation systems using actual systems. In addition to the ready-made process models, CIROS ® Advanced Mechatronics also offers you the option of simulating process models of your own design. You can create and modify process models using CIROS® Professional, which is a further application available from the CIROS® Automation Suite.


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Target group

The manual is intended for Trainers and teachers The manual provides them with ideas and suggestions as to how CIROS® Advanced Mechatronics can be used in lessons and in vocations and further training. Trainees and students For whom the information and instructions on how to operate CIROS® Advanced Mechatronics are of particular interest.

Structure of the manual

The manual is divided into the following subject areas: Chapter 2 contains information and instructions regarding the installation and licencing of CIROS® Advanced Mechatronics. Chapters 3 and 4 describe the system and the main operational functions of CIROS® Advanced Mechatronics. Chapter 5 deals with the didactic aspects and lists the training ®

contents taught with CIROS Advanced Mechatronics. It further represents the training concept and the resulting possibilities for use in lessons. Chapters 6 and 7 describe actual problems in relation to the training contents, methodological procedures towards solutions and implementation in CIROS® Advanced Mechatronics.

Conventions

Specific notation is used for texts and key combinations and key sequences to help you find information more easily.

Notation

Meaning

Bold

This format is used for command names, menu names, dialog box names, directory names and command options.

Key1+key2

A plus symbol (+) between the key names means that the keys quoted must be pressed simultaneously.

Key1‟key2

6

A minus symbol (-) between the key names means that the keys quoted must be pressed in sequence.



Additional support

Further descriptions and support is available via the online Help. The online Help consists of: ®

CIROS® Help for operation and CIROS Advanced Mechatronics Assistant.

CIROS® Help contains detailed information regarding the functions and operation of CIROS® Advanced Mechatronics. CIROS® Help is a component part of the CIROS ® Automation Suite and describes the functionality of various, different CIROS® applications. The functional scope of CIROS® Help is therefore greater than that required for CIROS® Advanced Mechatronics. The menu of the online Help provides functions that you are already familiar with from a standard Internet browser. These include: Next and Back, Select Home Page, Print Selected Topics, Show/Hide the Navigation bar or Set Options for Internet Connection. Moreover, via extension registers such as Content, Search, Favourites, you also have the option of conveniently navigating through the information in CIROS® Advanced Mechatronics Help. The CIROS® Advanced Mechatronics Assistant provides detailed functional descriptions and technical documentation regarding the individual stations. A sample PLC program is included for each station. The PLC program is created in STEP 7. Moverover, CIROS® Advanced Mechatronics Assistant offers you direct access to some ready made sample systems and prepared exercises. A Getting Started section is also integrated for a quick introduction to CIROS® Advanced Mechatronics. An Adobe Acrobat Reader must be installed on your PC to enable you to view PDF documents. The Adobe Acrobat Reader program is available free of charge and you can download this from the Internet address www.adobe.de. Our telephone hotline is available at any time, should you have any queries during the installation or operation of CIROS® Advanced Mechatronics.


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2. This is how you i nstall CIROS® Advanced Mechatronics

To install CIROS® Advanced Mechatronics you will need the CIROS ® Automation Suite DVD-ROM, where all the software packages of the ®

CIROS Automation Suite are ready for installation. It also includes the manuals in the form of PDF documents for the individual software packages. On completion of the installation, you will need to execute the licencing. As soon as this is successfully completed you can start CIROS ® Advanced Mechatronics. For further information regarding system requirements, installation and licencing, please refer to the enclosed instructions.

2.1 User-specific installation of default sample systems

To be able to simulate a modelled system, a PLC program must be available for each station of the system in order to control the operation of the station. Each station is equipped with an internal PLC to execute

and S7 programs used

PLC programs. A S7 simulator is used as internal PLC. If you are working with the default settings of CIROS ® Advanced Mechatronics, the prepared sample PLC program is automatically downloaded to the internal PLC and executed once simulation is started. This enables you to simulate the sample systems provided and any newly created system straight away and without errors. If you wish to modify one or several sample PLC programs, then the PLC programs must be installed in an additional subdirectory specified by you, where you can effect your changes. You can then download the modified programs to the appropriate station of your system and execute these. You can of course also download the modified PLC programs to an external PLC, in which case the respective station of the system using an external PLC.

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2. This is how you install CIROS ® Advanced Mechatronics

By using this procedure, the default PLC programs used by CIROS® Advanced Mechatronics remain unchanged and can be downloaded again to the internal PLC of a station. CIROS® Advanced Mechatronics supports you in the user-specific installation of the sample systems and S7 programms. To do so, open up CIROS® Advanced Mechatronics Assistant.

CIROS® Advanced Mechatronics differentiates between reference models und user models.

Reference modelsare sample systems which are filed in the program directory of CIROS® Advanced Mechatronics and are write protected. The model and associated PLC programs cannot be modified. This ensures that the process model can be opened and correctly simulated at any time.


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2. This is how you install CIROS ® Advanced Mechatronics

User models, if created and opened with the help of CIROS® Advanced Mechatronics Assistant, are filed as standard in your personal folder under own files\CIROS\CIROS Advanced Mechatronics Samples. These are not write protected and you therefore can for example modify the appropriate PLC programs and replace these with your own. The program directory with the user models represents your individual working environment for CIROS® Advanced Mechatronics. You can also copy the user models into a folder other than into the standard preset folder. You will find the information for this in CIROS ® Advanced Mechatronics Assistant. For the user modells created with the help of CIROS ® Advanced Mechatronics Assistant the following directory structure is created:

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3. The CIROS® Advanced Mechatronics system

The following form part of CIROS® Advanced Mechatronics: The simulation software CIROS® Advanced Mechatronics, The communication software EzOPC, The online CIROS® Advanced Mechatronics Help, An online CIROS® Advanced Mechatronics Assistant, An Online Help for EzOPC, A PDF document with information regarding the licencing and installation of a licence server, A manual in the form of a PDF document for the operation of CIROS ® Advanced Mechatronics.

3.1 Summary of CIROS® Advanced Mechatronics

CIROS® Advanced Mechatronics is a PC-based graphic 3D simulation system which serves as an introduction to automation systems with distributed intelligence. CIROS Advanced Mechatronics enables you to create, program and simulate distributed systems of varying complexity. A distributed system consists of one or several stations. One station is characterised by the fact that it independently executes specific machine functions; it is therefore an autonomous system part with its own PLC program.


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CIROS® Assistant

CIROS® Help

System consisting of station models Library with station models

Station 1

Station 2

Station 2 ...

Internal S7 PLC

Internal S7 PLC

Internal S7 PLC

Control functions

OPC-Client

EzOPC (OPC-Server)

Easy Port

S7-PLCSIM

CoDeSys PLCWinNT

External PLC

Component parts of CIROS ® Advanced Mechatronics

The following is required in order to simulate the operation of a distributed system: A graphic process model of the distributed system, A PLC program and PLC for each station, which autonomously controls the operation of the station and, if required, exchanges information with other stations, A simulator that simulates the behaviour of the system. This simulation ensures for example that cylinders move and sensors are actuated.

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Each station is stored in a library together with a sample PLC program. The PLC program defines a possible sequence of the station. You can of course create new PLC programs, which generate a different process sequence. If a system is now modelled from the prepared stations, the corresponding PLC program is automatically downloaded to the internal PLC of the station. A SIMATIC S7 simulator is used as internal PLC, which executes the PLC program once simulation is started. In order to ensure that the stations of the system interact correctly, they need to exchange information. The default communication links used between the stations are established automatically. This facility enables you to simulate the operation of a system immediately after modelling. The advantage of this is that you can familiarise yourself with, operate and observe the process without having to create the PLC programs for the individual stations beforehand. In the next step you can establish or change the communication links yourself and make the necessary adjustments in the PLC programs. One particular additional function provided by CIROS ® Advanced Mechatronics is the possibility of fault simulation, whereby it is possibly to set typical faults in the system. Possible causes of malfunction are for example a mechanically misadjusted sensor, a cable break or failure of a complete. The cause of the fault must be found by means of systematic fault finding and eliminated.


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The monitoring and analysing of processes and the elimination of faults is a focal point of CIROS® Advanced Mechatronics. A further focal point is the creation of your own PLC programs for individual stations. These PLC programs are downloaded to an external PLC and CIROS® Advanced Mechatronics exchanges the input/output signals with the external PLC via the OPC interface. The following are possible as external PLC: Any actual PLC, The Soft-PLC SIMATIC S7-PLCSIM, The soft PLC CoDeSys PLCWinNT. CIROS® Advanced Mechatronics requires the software program EzOPC for the link to an external PLC. The OPC server EzOPC communicates with any PLC via the EasyPort interface.

Note

In addition to the ready-made process models, CIROS ® Advanced Mechatronics also offers you the option of using process models of your own design. You can create and modify process models using CIROS ® Professional, which is a further application available from the CIROS ® Automation Suite.

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3.2 A distributed system in

Systems can be created from one or several stations. Each station represents an "intelligent unit", which independently executes specific

®

CIROS Advanced Mechatronics

machine functions. An "intelligent unit" consists of a station, a predefined sequence with predefined communication interface, a PLC program, an internal PLC and an optional robot program. The predefined sequence of the PLC controlled stations can of course be modified by the user. All stations are prepared for your use: Processing station, Fluidic Muscle Press station, Handling station Automated warehouse station, Storing station, Pick & Place station, Testing station, Buffer station, Quality assurance station, Robot station, Robot assembly station, Sorting station, Separating station, Pallet transport system with 6 working positions ‟ so-called docking positions - for MPS ® 500-FMS stations, Distributing station. Two types of system can be created from the stations listed above: MPS® Standard systems, MPS® 500-FMS systems.


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Example of an MPS® Standard system

Example of an MPS® 500-FMS system

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The stations are available from two libraries: The MPS® stations library, ®

the MPS 500-FMS library. Due to the technological functions of the individual stations and if using the prepared PLC programs, only specific combinations are permissible when modelling a system.

Note

A system can also be configured of only one station. This enables you to teach all the training contents for which only one individual station is required. MPS® systems perform different production processes: MPS® Standard systems perform the assembly of measuring instruments and short-stroke cylinders. ®

MPS 500-FMS systems include stock administration and assembly of short-stroke cylinders.

3.3 Communication in distributed systems

To ensure the correct sequence of the production process, the "intelligent units" of the system must exchange information. In other words, they need to communicate with one another. In MPS ® systems these are the individual stations. How and with whom the stations communicate depends on their position in the material flow. In the case of MPS® Standard systems a station usually communicates with the preceding and successor station. In the standard version, one bit is exchanged in each case. Information is exchanged via optical sensors. This type of coupling of stations is referred to as StationLink. Through-beam senor emitters and receivers are used as StationLink sensors.


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With MPS® 500-FMS systems, each station forming part of the transport system communicates with the transport system. Only in this way does the transport system know which stations are involved in the production process and in which working position these are. If two stations are in use at one working position, such as the distributing and testing stations at the position for incoming goods, an information exchange therefore also takes place between these two stations. All stations of an MPS® 500-FMS system communicate via the coupling of PLC inputs and outputs. This type of communication is known as I/O connection. In addition, the stations located at the working positions of the transport system use the optical sensors for information exchange. The part of communication conducted via I/O connection can be graphically projected and modified. If changes are made in the communication link, you need to make sure that the PLC programs of the respective stations make available the communication information accordingly and conversely also evaluate it again.

Projection and representation of communication links

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3.4 The preassembled station

The station models are realistic replications of existing stations. Apart from the graphic representation, each station model comes with a

®

models in CIROS Advanced Mechatronics

sample PLC program and, if required, a robot program.

Station model

Description Processing station This model is a simulation of the MPS ® processing station from Festo Didactic. On this station workpieces are to be tested, processed and transferred to the neighbouring station.

Fluidic Muscle Press station This model is a simulation of the Fluidic Muscle Press station from Festo Didactic. On this station workpiece inserts are to be pressed into the workpiece housings and the finished workpiece transported to the transfer position.


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Station model

Description Handling station This model is a simulation of the MPS ® handling station from Festo Didactic. On this station workpieces are to be removed from a mounting and, depending on the result of the material testing, deposited on a slide. The workpieces can also be passed on to a neighbouring station.

Automated warehouse station This model is a simulation of the automated warehouse station of Festo Didactic. On this station workpiece are to be stocked up and taken out.

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Station model

Description Storing station This model is a simulation of the storing station of Festo Didactic. Depending on the position of the station within the material flow, workpieces are to be either stocked up or taken out.

Pick & Place station This model is a simulation of the Pick & Place station of Festo Didactic. On this station workpieces are to be placed onto workpiece housings and the complete workpiece is transported to the transfer station.


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Station model

Description Testing station This model is a simulation of the MPS ® testing station from Festo Didactic. On this station the material condition of the workpieces is to be established and the workpiece height checked. Depending on the test result, the workpiece is to be ejected or transferred to the neighbouring station.

Buffer station This model is a simulation of the MPS ® testing station from Festo Didactic. On this station workpieces are to be transported, buffered and separated.

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Station model

Description Quality assurance station This model is a simulation of the MPS ® quality assurance station from Festo Didactic. On this station the shape tolerance of workpieces is to be tested.

Robot station This model is a simulation of the MPS ® robot station from Festo Didactic. On this station workpieces are to be sorted according to colour and the correct alignment of workpieces monitored. Depending on the result, workpieces are sorted into different magazines and passed on to the neighbouring station.


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Station model

Description Robot assembly station This model is a simulation of the MPS ® robot assembly station from Festo Didactic. On this station a model cylinder is to be assembled from a basic body.

Sorting station This model is a simulation of the MPS ® sorting station from Festo Didactic. On this station workpieces are to be sorted according to material and colour.

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Station model

Description Transport system station This model is a simulation of the MPS ® transport system station from Festo Didactic. On this station workpieces are to be transported to the individual station of an MPS® 500FMS system.

Separating station This model is a simulation of the MPS ® separating station from Festo Didactic. On this station the material flow is split The basic body for the cylinder is transferred to conveyor 1 and the housing for the measuring instrument is transported to conveyor 2 and transferred to the neighbouring station.


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Station model

Description Distributing station This model is a simulation of the MPS ® distributing station from Festo Didactic. On this station workpieces are to be separated and passed on to the neighbouring station.

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3.5 Controlling a station with

Each station in CIROS ® Advanced Mechatronics has an integrated

internal PLC

LDR, FCH, STL and GRAPH programs created in STEP 7.

SIMATIC S7 simulator as internal PLC. The S7 simulator can execute

When you start the simulation of a system, the internal PLC executes the sample PLC program forming part of the station. This enables you to familiarise yourself with the running of a system immediately after modelling in the simulation. Detailed information regarding the functional scope of the internal PLC can be found on the CIROS® online Help.


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3.6 Controlling a station with

If you are creating and testing your own PLC programs for the individual

external PLC

to an external PLC and execute them from this. The advantage of this is that you can use the PLC and the programming system of your choice.

stations of a system, we recommend that you download the programs

Also, the testing and diagnostic functions provided by the programming system are thereby available to you in the PLC program for fault finding. This includes the status display of PLC input/outputs and variables, the online display of the PLC program and also the read-out of machine statuses. You do not need any additional hardware components if you use the Soft-PLC S7-PLCSIM or CoDeSys SP PLCWinNT as external PLC.

Station of a system

PLC programming system STEP7

Soft PLC S7 PLCSIM

Information exchange with configuration using the external Soft-PLC S7-PLCSIM

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If you use a hardware PLC as external PLC, you will need EasyPort and the data cable for the exchange of input/output signals. EasyPort transmits the input/output signals of the PLC to the OPC server EzOPC via the serial or USB interface of the PC. The OPC server passes on the data to the selected station during the system simulation and, conversely, the statuses of the sensors and actuators of the corresponding station are communicated to the external PLC.

Station of a system


EasyPort

PLC

Information exchange with configuration using an external hardware PLC


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3.7 Functions for setting

The dialog to set faults in a system is password protected. Access to

faults in a system

A list of typical faults is available for each station. Select one or several faults from this list.

this dialog is available solely to trainers and teachers.

The task for trainees is to identify and describe the fault occurring during system operation and to subsequently determine the cause of the fault. The trainees enter the suspected fault in the dialog box for error elimination. If the fault has been correctly identified, the system then operates correctly. The entries in the dialog box for fault elimination are logged and can be viewed by trainers and teachers.

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3.8 Functions for analysing a system

With CIROS® Advanced Mechatronics, you have numerous options to monitor and analyse the operation of a system. As soon as system simulation is active and the PLC programs of the individual stations control the operation of the system, you can operate and visually monitor the process. The process is controlled via the pushbuttons and switches of the individual control consoles.


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LEDs on the sensors and valves indicate the electrical status of the process components. LEDs on the PLC inputs and outputs on the control console indicate the status of the communication realised via these inputs and outputs. If compressed air is applied to a cylinder connection, then the connection is highlighted in blue. The compressed air tubing itself is not simulated. The statuses of the PLC inputs/outputs are shown in separate windows. A Manual Operation window provides an overview of all process statuses and process activities. In the Manual Operation window you can also display the communication links between two selected stations. If you want to execute the sequence step-by-step, then use the Manual Operation window as tool for control. By setting stops, you can stop the process at defined points. If a PLC program is not active during system simulation, you can use the Manual Operation window to activate individual process activities, whereby you can for example control the movement of a cylinder or the switching on or off of an electric motor.

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3.9 Directory and file

Here you obtain information about the directory and file structure of CIROS® Advanced Mechatronics. ®

structure of CIROS Advanced Mechatronics

This information is useful if, You want to make available the model of a system to other users, You want to modify the sample PLC programs for the individual stations of a system.

Directory structure following the installation

The following directory structure is created if you install CIROS ® Advanced Mechatronics with the default settings offered.

of CIROS® Advanced Mechatronics


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rograms . . . ciros advanced mechatronics.en bin FD_PLC_ADV ...

. .

MB4 S7

.

. . .

313c___1

PLC programs for MPS 500-FMS stations

FMS50__1

PLC program for MPS 500-FMS transport system

MPSC_V22

PLC programs for MPS Standard stations

Store

PLC program for MPS 500-FMS automated warehouse station

Samples Models MPS 501-FMS system

MPS500-FMS51 Model

Workcell for MPS 501-MPS system

Programs MPS500-FMS57

PLC program for MPS 501-FMS system MPS 507-FMS system

MPS System with separating

MPS Standard system with separating station

Multi-Bit-IO MPS VE-PR

MPS Standard system with distributing and testing stations (multi bit communication) Model Programs

One-Bit-IO MPS VE-PR MPS VE-PR-SO

Programs

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MPS Standard system with distributing and testing stations (one bit communication) MPS Standard system with distributing, testing and sorting stations (one bit communication) PLC and robot programs for all MPS stations



The S7 project with the sample PLC programs for the individual stations is stored in the directory S7. These srcinal PLC programs must not be

modified! The same applies to S7 programs and process models in the folder Samples. If you want to modify one or several of the sample PLC programs or of the process models, you need to copy the directory Samples in another subdirectory defined by you, where you carry out your modifications. You can then download the modified programs to the internal PLC of the appropriate station and execute it. With this procedure, the default PLC programs used by CIROS ® Advanced Mechatronics remain unchanged and can be reloaded again to the internal PLC of a station at any time. CIROS® Advanced Mechatronics Assistant helps you copy models and example PLC programs. For easy identification, copied models are called user models and the srcinal models are called reference models.

Project structure for the modelled systems

The example of a system is used to show what files form part of a modelled system and what information is stored in these files. A system is also known as a process model or workcell. All files which are part of the graphic representation of the system are filed in the user-defined subdirectory. If additional CIROS® Advanced Mechatronics systems are also stored in the subdirectory viewed, then files with corresponding names are also available for these systems. Moreover the list of bmp files is more extensive. It is however difficult to allocate bmp files to individual systems.


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File

Description

Example.mod Example.ini

Process model of a system named Example. Initialisation of the process model: The file contains all user-specific settings for the process model such as window configuration, fault settings, etc. It also contains a reference to the location and name of PLC programs to be executed after simulation of the internal PLCs of the stations is started.

Example.prot

Log of fault localisation: The file is read in teacher mode and displayed in the fault log window.

Example.htm

Exporting of fault log:

Example.xls Example.txt Example.mcf

Modifications in the fault log are automatically exported into these files. These files can then for example be viewed via Microsoft Internet Explorer or Microsoft Excel. Fault settings: This file contains all the settings regarding the activation, start, duration and type of a fault. If this file exists in the process model directory, it overwrites the settings in the ini-file. If it does not exist, then the fault settings filed in the ini-file are used.

*.bmp

Various bitmap files required for the graphic display of the system. The bitmap files required are dependent on which stations are used in the system.

Files for a process model

A system also includes PLC programs, which are executed either via an internal or external PLC. These PLC programs control the running of individual system stations. The file *.ini includes a reference to the memory location of the PLC programs.

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You need to keep this in mind if you want to copy a system you have modelled yourself to another PC and simulate from there. If you want to copy the process model of a system, the best way to proceed is as follows: Select all the files forming part of the system. These are all the files, which have the name of the respective system and all the bitmap files. Copy the selected file to a subdirectory of the desired PC. The subdirectory on the target PC must have the same name and the same path as on your PC. If the station is operated using the sample PLC programs, make sure that the sample PLC programs on the new PC are stored in the same path as on your PC. If this is not the case, start CIROS ® Advanced Mechatronics on the new PC and download the copied process model. Then download the desired PLC program from the relevant directory on the new PC to the internal PLC of the individual system stations. By downloading the PLC programs, the reference in the ini file to the memory location of the PLC programs is automatically corrected. The system can now be simulated. If one or several stations of the system are controlled via your own created PLC programs, then these programs must also be available on the new PC. The PLC program must be downloaded to the corresponding system stations on the new PC.


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4. Main control functions of CIROS® Advanced Mechatronics

This chapter describes the main control functions of CIROS ® Advanced Mechatronics. Various options to activate commands are available via MS Windows programs. In this description, commands are triggered via entries in the menu bar. You can and should of course use the symbols bar, appropriate key combinations or the context-sensitive menu with the right mouse button. Detailed information regarding the use of all the options of CIROS® Advanced Mechatronics can be found in the online Help for this software package.

Note

To enable you to create a wide range of different system, the library has been extended with the addition of new station models. The new standards regarding circuit diagram design are taken into consideration in the PLC programs and circuit diagrams. "Old" and "new" standards differ with regard to the designations of valve coils, pushbuttons and switches as well as indicator lights.

4.1 Creating a new MPS® Standard system from preassembled station models

The stations models for the configuration of a system are available in two libraries: MPS® stations library, MPS® 500-FMS library. If you want to model a new MPS® Standard system, then use the models from the MPS® stations library. This library contains the station models for the following: Processing station, Fluidic Muscle Press station, Handling station, Storing station, Pick & Place station, Testing station, Buffer station, Robot station,

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4. Main control functions of CIROS ® Advanced Mechatronics

Robot assembly station, Sorting station, Separating station Distributing station. Station models for an MPS® Standard system are arranged directly next to one another. The alignment and connection of models is effected in a simple way via specified coupling points on the models. The automatic alignment ensures that the StationLink sensors of neighbouring stations are also correctly positioned. The StationLink sensors are optical sensors which transmit the communication signal.

Note

A system can also be configured of just one station, whereby you can teach all the training contents in CIROS® Advanced Mechatronics for which only a single station is required.

Due to the technological functions of the individual stations, only certain combinations are permissible when modelling a system. The possible combinations, i.e. subsequent stations, are indicated with grey shading.


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This is how you combine your ®

MPS Standard stations

–

g n ti u b ir t s i D

d r a d n a t S

d te s u j d a – t n ti u b ir t s i D

d e t s g n ti s e T r o f

g in t s e T

g n i s s e c o r P

jd u a –

g in l d n a H

n io t a t s r o s s e c c u s r o f

d te s ju d a –

g in l d n a H

n io t a n i m r e t r o f

r fe f u B

e c a l P & k c i P

Distributing ‟ Standard Distributing ‟ adjusted for testing Testing Processing Handling ‟ adjusted for successor station Handling ‟ adjusted for termination Buffer Pick & Place Fluidic Muscle Press Separating Storing ‟ Stock up Storing ‟ Take out Robot Robot assembly Sorting

Permissible station combinations for MPS ® Standard systems

40



This is how you combine your ®

MPS Standard stations

s s e r P e l c s u M c i id u l F

c k o t S

t u o e k a T

–

–

p u g n ti a r a p e S

g n ri o t S

g n ri o t S

t o b o R

y l b m e s s a t o b o R

g n tir o S

Distributing ‟ Standard Distributing ‟ adjusted for testing Testing Processing Handling ‟ adjusted for successor station Handling ‟ adjusted for termination Buffer Pick & Place Fluidic Muscle Press Separating Storing ‟ Stock up Storing ‟ Take out Robot Robot assembly Sorting

Permisible station combinations for MPS ® Standard systems


41


The distributing, handling and storing stations are available in two variants. Depending on the combinations in which the stations are used, individual sensors and stops are differently positioned and adjusted. The distributing station can deposit workpieces at two different transfer positions. The sensors which determine and detect the swivel angle on the transfer module must be correspondingly set. The lower transfer position is required for the testing station; all other stations operate using the higher transfer position. The distributing station variants are therefore correspondingly designated with distributing station –

adjusted for testing station and distributing station – standard design. The handling station can deposit workpieces at two different positions: Internally on the station or externally at the transfer position of the sucessor station. The sensor which determines the transfer position of the axis must be correspondingly positioned. If the handling station forms the end of a system, then the workpieces are deposited on the station itself. In this case you will require the variant handling station – adjusted for termination. If there is a successor station, the workpieces are deposited on the transfer position of the successor station. This variant of the handling station is referred to as handling station – adjusted for successor station. The robot station can also deposit workpieces at two different positions: Internally on the station or externally on the transfer position of the successor station. The robot program automatically detects whether or not a neighbouring station follows and adapts the robot movement accordingly. This station can therefore both be used in the middle of or as a last station in a production system. Two sequences are available for the storing station: The station can stock up or take our workpieces. Each sequence is realised via a separate PLC program. If the station is at the beginning of the material flow it thus forms the first station of a system ‟ consequently workpieces are taken out. In this case you will require the variant Storing Station ‟ Take out. If the storing station forms the end of a system, then you use the variant Storing Station ‟ Stock up.

42



The operation of the system with the prepared PLC programs can only be simulated fault-free if a system is correctly assembled. The modelling of an MPS® Standard system is explained with the help of an example. A combination consisting of the distributing, testing and sorting stations is to be configured.

This is how you create an MPS® Standard system An MPS® Standard system consisting of the distributing, testing and sorting stations is to be created. 1. Start CIROS® Advanced Mechatronics. When CIROS® Advanced Mechatronics is started, both the activity window and the help window are opened.


43


Note

In CIROS® Advanced Mechatronics Assistant open the folder which contains the required process model. This is where a functional description and technical documentation regarding the model are available. In addition, you can download a few prepared sample systems directly from the Assistant. If you do not require the information of the Assistant when starting CIROS® Advanced Mechatronics, deactivate the entry Open Automatically of the assistant in the Help menu.

2. Activate the command New in the File menu. Click onto MPS® System. The window Create MPS® System is now displayed. 3. Select a directory as memory location for the new system and enter the file name. Under file type, select CIROS® Workcells (*.mod). Then click onto Save.

44



4. The model of a blank system is displayed. By creating a new system, a number of the following settings are automatically effected in ®

CIROS Advanced Mechatronics: ‟ The change into Edit Mode is effected, ‟ A table with the possible workpieces is made available, ‟ The view selected is Top View, ‟ The Model Libraries window is open.

5. A brief description of the model selected is displayed when you click onto Details in the Model Libraries window. Detailed information regarding the models in the library is available on the online Help in the chapter CIROS® Advanced Mechatronics. You start Help by activating the command Examples and models of CIROS® Advanced Mechatronics in the menu Help.


45


6. First add the distributing station model. The distributing station is available in two variants. Since the testing station follows the distributing station in the sample system, select the entry Distributing Station – Adjusted for Testing Station under MPS®

Stations. A preview then displays the model. Now click onto the Add button. Alternatively, add a model by double clicking on the relevant model corresponding model entry. The system now consists of the distributing station – adjusted for testing station model. The distributing station is shown in green as it is still highlighted. Moreover the distributing station is connected automatically to the workpiece table, since it has been added as the first station.

46



7. Click outside of the station to cancel the highlighting. A coupling point is shown on side of the station, which indicates that the distributing station can be connected to a further station at this point.


47


8. If the representation of the station is too small, you can change this using the commands in the View menu.

48



9. Make sure that the Edit Mode is selected. You can establish this by the check mark next to the Edit Mode command in the Modeling menu. Now add the testing station as an additional station.


49


10. All stations are added at the same position in the workspace. Move the newly added testing station, by highlighting the testing station and, by holding down the left mouse button, moving the mouse pointer to the desired position.

11. The two models are next to one another, but are not yet connected. In order to ensure that the operating and transfer points coincide during the production run of the system, the station models must be appropriately aligned and connected.

50



12. Now align the testing station model with the distributing station model. To do so, click onto the lower, grey shaded coupling point of the testing station. Hold down the left mouse button and drag the coupling point to the coupling point of the distributing station. The testing station is now connected to the distributing station.


51


13. Add the sorting station as the last station. This station is also shown at the predefined position in the activity window.

52



14. Click onto the newly added, still highlighted station and move it up next to the testing station.


53


15. Connect the sorting station model with the upper free coupling point of the testing station model. To do so, click onto the grey shaded coupling point of the sorting station. Hold down the left mouse button and drag the coupling point to the free coupling point of the testing station. The highlighting of the model is cancelled as soon as you click outside of the station model.

16. The system is configured. The communication links, realised via optical sensors, are automatically established via the correct positioning and connecting of the stations.

54



Exit the edit mode as soon as your system is configured. Change to the

view mode to obtain a realistic 3D representation of the system.

Note

It is not absolutely necessary to connect the workpiece table to a station. You can position the workpiece table at any point within the workspace.


55


This is how you change to the view mode

1. Deactivate the Edit Mode command in the Modeling menu by clicking onto the Edit Mode command. The check mark next to the

Edit Mode is removed. 2. A 3D representation of your system is now displayed. A top view is also shown.

3. Close the Model Libraries window and select a perspective view of the system.

56



4. To obtain a perspective view of the 3D model, select for example the command Standard Views/Default Settings in the View menu. With the commands under View you can move, rotate or zoom to obtain an appropriate view of your system.

The system is correctly configured and connected. You can now simulate system production right away.


57


Note

Once you have created or modified a system, a Save prompt will be displayed when you close the process model. If you want to save the changes, answer the prompt with Yes or answer with No if you want to discard the changes.

4.2 Creating an MPS® 500FMS system from preassembled station models

The station models to configure a system are available in two libraries: MPS® Stations library, MPS® 500-FMS library. If you want to model an MPS® 500-FMS system, then use the station models from the MPS® 500-FMS library. The possible configuration levels of an MPS® 500-FMS system are based on the full configuration of the MPS® 500-FMS system, where all six working positions on the transport system are occupied by a station or a combination of stations.

58



Stock

Product output

S

HL

Assembly

RM

Small parts store

Presorting

HH

P

H

V

B

Product input

VI

Processing

Qualityassurance

V: Distributing station

P: Testing station

HL: Automated warehouse station

H: Handling station

B: Processing station

HH: Handling station

VI: Quality assurance station

RM: Robot assembly station

S: Sorting station

Full configuration of an MPS® 500-FMS system

®

The following form part of a full configuration of an MPS 500-FMS system: Pallet transport system station with 6 working positions for MPS ® 500-FMS stations, Station combination consisting of distributing and testing stations, Station combination consisting of handling and processing stations, Quality assurance station,


59


Robot assembly station, Automated warehouse station, Station combination consisting of handling and sorting stations. The following rules apply to create MPS® 500-FMS systems in different configuration stages: Only the listed six stations or station combinations can be positioned on the transport system. For each station or station combination, there is exactly one permissible working position in the transport system. The position can be seen from the full configuration of an MPS® 500-FMS system. Individual "positions" on the conveyor can remain unoccupied, whereby individual stations or station combinations and their associated production steps are omitted. Example: The smallest MPS ® 500-FMS system consists of the transport system station, the distributing and testing stations combination for product input and the handling and processing stations combination for product output. The positioning and alignment of the models is effected simply via the specified coupling points on the models. In the case of MPS® 500-FMS systems, the station models are aligned with the transport system model and connected to it. The connection or coupling points correspond to the stopper positions of the transport system. As a result of establishing the connections, the default communication links used are also simultaneously established. The operation of the system can only be simulated error-free if a system is correctly configured. The modelling of an MPS® 500-FMS system is shown using a simple example. The sample system consists of a transport system, the distributing and testing stations in the form of product input, the handling and processing stations combination at the position for processing and the handling and sorting stations in the form of product output.

60



This is how you create an MPS® 500-FMS system ®

1. Start CIROS ®Advanced Mechatronics. When CIROS Advanced Mechatronics is started both the activity window and the Help window are displayed.

Note

In CIROS® Advanced Mechatronics Assistant open the folder which contains the required process model. This is where a functional description and technical documentation regarding the model are available. You can also download some prepared sample systems directly from the Assistant. If you do not need the information of the Assistant when starting CIROS® Advanced Mechatronics, then deactivate the entry for automatically opening the Assistant in the Help menu.


61


2. Activate the New command in the File menu. Click onto MPS®

System. ®

The Create MPS System window is now displayed. 3. Select a directory to store the new system. Enter the file name. Under file type, select CIROS® Workcells (*.mod). Then click onto the Save button.

62



4. The model of a blank system is now displayed. By creating a new system, some settings in CIROS® Advanced Mechatronics are automatically effected such as: ‟ Changing into the Edit mode, ‟ A table with possible workpieces is made available, ‟ The view selected is Top View, ‟ The window Model Libraries is open.

5. A short description of the selected model is displayed if you click onto Details in the Model Libraries window. Detailed information regarding the models in the library is available on the online help in the chapter CIROS® Advanced Mechatronics. Help is started by activating the command Examples and Models of CIROS® Advanced Mechatronics in the Help menu.


63


6. First, insert the transport system model from the MPS® 500-FMS library by clicking onto Transport System. A preview then displays the model. Now click onto the Add button. Alternatively, you can add a model by clicking onto the corresponding model entry. The system now consists of the model of the transport system, which is shown in green as it is still highlighted.

64



7. Click outside of the model to cancel the highlighting. Three coupling points are shown on each of the longitudinal sides of the transport system model. These indicate that the transport system model can be connected with additional models at these points.


65


8. Move the transport system model into the centre of the workspace. To do so, highlight the model via a mouse click. Then drag the mouse pointer to the desired position by holding the left mouse button down.

66



9. Now add the station combination for product input as a further model by double clicking onto Product Input.


67


10. All stations are added at the same position in the workspace. Move the newly added product input station combination. The operating position for product input is at the bottom left of the transport system.

11. The two models are next to one another, but are not yet connected. To ensure that the operating and transfer points coincide during the production run of the system, the models must be appropriately aligned and connected.

68



12. Now align the model for product input with the transport system model by clicking onto the grey shaded connecting point of the stations for product input. Hold down the left mouse button and drag the connecting point onto the connecting point of the transport

system. The station combination for product input is now connected to the transport system.


69


13. Next enter the station combination for the processing sequence by double clicking onto Processing in the MPS® 500-FMS library. This station combination is also shown at the predefined position in the activity window.

70



14. Connect the newly added, still highlighted model to the lower middle connecting point of the transport system model by clicking onto the grey shaded coupling point of the highlighted processing model. By holding down the left mouse button drag the coupling point to the lower, middle coupling point of the transport system model.


71


15. Finally, add the model for product output. Again, this model is shown at the predefined position in the activity window.

72



16. Move the newly added product output station combination. The operating position for product output is at the top left of the

transport system.


73


17. Connect the product output model to the top left connecting point of the transport system. The highlighting of the model is cancelled as soon as you click outside of the station model.

18. The system is created. The default communication links used have been automatically established during modelling of the system. 19. Now exit the Edit Mode and change to the View Mode to obtain a realistic 3D representation of the system.

74



This is how you change into the view mode

1. Deactivate the Edit Mode command in the Modeling menu by clicking onto the Edit Mode command. The check mark next to Edit

Mode is removed. 2. A 3D display of your system is now displayed which also includes a top view.

3. Close the Model Libraries window. This will give you more space for the system representation.


75


4. To obtain a perspective view of the 3D model, select for example the

Standard Views/Default Settings command in the View menu. With the commands under View you can move, rotate and zoom to obtain an appropriate view of your system.

76



5. The workpiece table can be positioned at a different point within your workspace at any time. Activate the Edit Mode command in the

Modeling menu and move the workpiece table to the desired position. Deactivate the Edit Mode command in the Modeling menu and generate an appropriate view of the system.

The system is created and correctly connected. You can now simulate system product straight away.


77


Note

If you have newly created or modified the process model of a system, a save prompt will be displayed when you close the process model. If you want to save the changes, then answer the prompt with Yes, or answer the prompt with No, if you want to discard the changes.

4.3 Modifying an existing system

You can modify the model of a system and for example add further stations. How you proceed for this and what you need to observe depends on what communication links are to be used within the system. In MPS® Standard systems, optical sensors are used as standard to effect communication. If the stations of an MPS® Standard system are correctly positioned and connected, using the connecting points, then the communication links are automatically established by means of this process. If you change an MPS® Standard system for which you have realised multi-bit communication via I/O connection, then the communication links must be re-established. If you only use the default communication links prepared and want to establish these, then activate the command Create Communication Links in the Modeling menu. All other communication links are to be established in the Manual

Operation window. Multi-bit communication via I/O connection is available as standard in MPS® 500-FMS systems. When modelling, or also modifying such a system, the communication links are set up automatically. However, if you modify an MPS ® 500-FMS system where you are not using the prepared default communication links, you need to set up the communication links yourself after modelling. User-defined communication links are set-up in the Manual Operation window.

78



This is how you modify an already created system ®

1. Start CIROS Advanced Mechatronics. 2. Download the desired system by activating the Open command in the file menu. 3. The Open File window is now displayed. Workcell (*.MOD) must be set as file type. Change into the directory in which the process model of the system is stored. Select the desired file and click onto the Open button.

4. View mode is set as standard. To change the system, change into edit mode by activating the Edit Mode command in the Modeling menu.


79


5. If you want to display information regarding the individual stations of the system, you need to highlight the respective station via a mouse click. Highlighted stations are shown in colour.

80



6. Open the context-sensitive menu via the right mouse button. Activate the Properties command. The Object Properties window is now open. The name indicates that the highlighted station is a testing station. Close the window when you have obtained all the necessary information.

Note

You will need the Object Properties function if you use a station in a system several times and wish to identify the individual stations. You identify a station by its name. Example: If you are using the buffer station twice in your system, the name of the station added first is Buffer and the name of the subsequently added buffer station is Buffer_1.


81


7. If you now wish to add another station to your system, change to the top view representation in View by activating the Standard

Views/Top View command in the View menu.

82



8. Select an appropriate representation of the system via zooming, moving or rotating the system.

9. Make sure that edit mode is selected. You can establish this by the check mark next to the command Edit Mode in the Modeling menu. 10. Now open the model libraries by activating the Model Libraries command in the Modeling menu. 11. In the case of the sample system, this is an MPS ® Standard system. For modifications to the system, you will need the stations of the MPS® Stations library. Open the library by clicking onto the + symbol in front of MPS® Stations library.


83


12. Carry out your modifications to the system. If you want to expand the system by adding assembly functions, then add for example the Pick & Place and Fluidic Muscle Press stations between the sorting and testing stations.

84



13. To add the desired stations, highlight the sorting station and move it up.


85


14. Now insert the Pick & Place station by double clicking the library entry Pick & Place Station .

86



15. Position the added station next to the testing station by clicking onto the highlighted Pick & Place station and move the mouse pointer to the desired position by holding down the left mouse button.


87


16. Connect the new Pick & Place station to the testing station by clicking onto the bottom, grey shaded coupling point of the Pick &

Place station. Drag the coupling point to the coupling point of the testing station by holding down the left mouse button. The testing and Pick & Place stations are now interconnected.

88



17. Use the same method to add the Fluidic Muscle Press station. Connect this station to the Pick & Place station.


89


18. Finally, connect the sorting station to the Fluidic Muscle Press

station. To do so, highlight the sorting station. Then drag the coupling point of this station to the unoccupied coupling point of the Fluidic

Muscle Press station whilst holding the left mouse button.

19. The changes to the system are completed. The communication links, realised via the optical StationLink sensors, are automatically set up via the correct positioning and connection of the stations. Close the library and change to the view mode to obtain a realistic 3D display of the system.

90



20. Deactivate edit mode in the Modeling menu by clicking onto the

Edit Mode command. The check mark next to Edit Mode disappears.


91


21. To obtain a perspective view of the 3D model, select for example the

Standard Views/Default Settings command in the View menu. By using the commands under View you can move, rotate or zoom to obtain an appropriate view of your system.

22. Save the modified status of the system by activating Save in the File menu if you want to keep the current file name. Select the Save as command if you want to save the system under a new name.

92



Note

In the same way as you can expand a system by adding new stations you can also remove existing stations of a system, whereby you proceed as follows: Highlight the respective station. Open the context-sensitive menu via the right mouse button, where you activate the Remove command. The station highlighted is removed.

4.4 Creating and monitoring communications links in a system

MPS® Standard systems

In MPS® system, the communication exchange is realised differently between the individual stations of a system.

In an MPS® Standard systems, communication takes place in the form of 1-bit connection via optical sensors as standard. As soon as the stations of a system are correctly positioned and connected with the help of the coupling points, the optical sensors are also correctly positioned to transmit communication signals. The prerequisites for error-free transmission of communication information are therefore in place. The absolute addresses of the PLC inputs and outputs of a station connected to the optical sensors can be found in the allocation list of the sample PLC program. You will find the technical documentation and information regarding the sample PLC program in the CIROS® Advanced Mechatronics Assistant. To open the CIROS® Advanced Mechatronics Assistant, activate the Examples and Models of CIROS® Advanced Mechatronics command in the Help menu. If you have expanded the 1-bit communication in a MPS ® Standard system to multi-bit communication via I/O connection, then you will need to create the additionally required communication links in the virtual system. Only if these communication links have been set up, can the information exchange between the system stations take place during simulation.


93


Different PLC inputs and outputs are available for the transmission of communication information. To enable you to work with a networked system promptly, the communication links between the stations are already prepared. You can establish these at the click of a button (Modeling/I/O Configuration/Create Communication Links), whereby specific PLC outputs of a station are connected to specific PLC inputs of neighbouring stations. Conversely, a number of PLC inputs of a station are of course also connected with PLC outputs of neighbouring stations. You can see all I/O communication links set up for an MPS ® system in the Manual Operation window. The prepared default communication links are shown as examples for an MPS® Standard system. The system consists of the distributing, testing and sorting stations. If other MPS ® Standard stations are integrated into a system, the connections between the stations are set up along the above lines.

94



Distributing station Optical sensors

Testing station

IP_FI 

Control

I4

Q6

console

I5 Q4  Q5 

Q7 I6 I7



IP_N_FO

IP_FI





I4

Q6









Q7 I6 I7





I5 Q4  Q5 



COMM_I0 COMM_I1

COMM_Q4 COMM_Q5



outputs for communication

COMM_I2 COMM_I3 COMM_Q0

COMM_Q6 COMM_Q7 COMM_I4



COMM_I5 COMM_I6 COMM_I7



    

IP_N_FO 





Additional PLC inputs/

COMM_Q1 COMM_Q2 COMM_Q3

Sorting station





I4

Q6









I5 Q4  Q5 

Q7 I6 I7

COMM_I0 COMM_I1

COMM_Q4 COMM_Q5











    

   

COMM_I0 COMM_I1

COMM_Q4 COMM_Q5





The prepared default communication links for an MPS ® Standard system

Note

PLC input I5 must be used for communication transfer. Input I5 is coupled to an EMERGENCY-STOP and indicates whether or not EMERGENCY-STOP is available. PLC inputs/outputs COMM_I0 to COMM_I7 and COMM_Q0 to COMM_Q7 are only available in the case of the virtual MPS ® stations for communication. Real MPS® stations do not have these inputs/outputs for communication as standard. The tables below list the allocation of the symbolic PLC addresses used for communication to the absolute PLC addresses.


95


Distributing station

Testing station

Sorting station

Symbolic address

Absolute address

Symbolic address

Absolute address

Symbolic address

Absolute address

IP_FI

I0.7

IP_FI

I0.7

IP_N_FO

Q0.7

IP_N_FO

Q0.7

I4

I1.4

I4

I1.4

I4

I1.4

I5

I1.5

I5

I1.5

I5

I1.5

I6

I1.6

I6

I1.6

I6

I1.6

I7

I1.7

I7

I1.7

I7

I1.7

Q4

Q1.4

Q4

Q1.4

Q4

Q1.4

Q5

Q1.5

Q5

Q1.5

Q5

Q1.5

Q6

Q1.6

Q6

Q1.6

Q6

Q1.6

Q7

Q1.7

Q7

Q1.7

Q7

Q1.7

COMM_I0

I2.0

COMM_I0

I2.0

COMM_I0

I2.0

COMM_I1

I2.1

COMM_I1

I2.1

COMM_I1

I2.1

COMM_I2

I2.2

COMM_I2

I2.2

COMM_I2

I2.2

96




Testing station

Sorting station

Symbolic address

Absolute address

Symbolic address

Absolute address

Symbolic address

Absolute address

COMM_I3

I2.3

COMM_I3

I2.3

COMM_I3

I2.3

COMM_I4

I2.4

COMM_I4

I2.4

COMM_I4

I2.4

COMM_I5

I2.5

COMM_I5

I2.5

COMM_I5

I2.5

COMM_I6

I2.6

COMM_I6

I2.6

COMM_I6

I2.6

COMM_I7

I2.7

COMM_I7

I2.7

COMM_I7

I2.7

COMM_Q0

Q2.0

COMM_Q0

Q2.0

COMM_Q0

Q2.0

COMM_Q1

Q2.1

COMM_Q1

Q2.1

COMM_Q1

Q2.1

COMM_Q2

Q2.2

COMM_Q2

Q2.2

COMM_Q2

Q2.2

COMM_Q3

Q2.3

COMM_Q3

Q2.3

COMM_Q3

Q2.3

COMM_Q4

Q2.4

COMM_Q4

Q2.4

COMM_Q4

Q2.4

COMM_Q5

Q2.5

COMM_Q5

Q2.5

COMM_Q5

Q2.5

COMM_Q6

Q2.6

COMM_Q6

Q2.6

COMM_Q6

Q2.6

COMM_Q7

Q2.7

COMM_Q7

Q2.7

COMM_Q7

Q2.7

Allocation of symbolic PLC addresses to the absolute PLC addresses for a number of MPS ® Standard stations

MPS® 500-FMS systems

In MPS® 500-FMS systems, multi-bit communication is available as standard. Multi-bit communication is essentially realised via I/O connection. However, in addition to the coupling of PLC inputs and outputs, the optical StationLink sensors are used for the transmission of communication information. As soon as the stations of a system are correctly positioned and connected by means of the coupling points, the prepared default I/O communications links are also automatically established.


97


The information exchange between the system stations during simulation can take place. Both the absolute and symbolic addresses of the PLC inputs/outputs of a station used for communication can be found in the allocation list of the sample PLC program. Technical documentation and information regarding the sample PLC program of a station can be found in CIROS® Advanced Mechatronics Assistant. To open CIROS® Advanced Mechatronics Assistant, activate the

Examples and Models of CIROS® Advanced Mechatronics command in the Help menu. Different PLC inputs and outputs are available for the transmission of communication information. To enable you to work promptly with a networked system, the communication links between the stations are prepared. They are automatically established during modelling or via the press of a button (Modeling/I/O Configuration/Create Communication Links), whereby specific PLC inputs and outputs of a station are connected to the PLC inputs and outputs of neighbouring stations. The sample PLC programs provided use a part of these communication links. The communication interfaces between all stations are described in CIROS® Advanced Mechatronics Assistant. All I/O communication links established for an MPS ® system can be identified in the Manual Operation window. The prepared communication links are shown as examples for an MPS ® 500-FMS system. The station consists of the transport system station and the distributing and testing stations in the form of product input.

98




Optical sensors

Testing station

IP_FI 

Control

I4

Q6

console

I5

Q7



IP_N_FO

IP_FI









 I4

Transport system station

ST1_OUT0

 I5



ST1_OUT1 ST1_OUT2

I6  Q4  Q5 

I6 I7



 Q4



 Q5



Additional PLC inputs/ outputs for



communication

COMM_I3 COMM_Q0 COMM_Q1

COMM_Q7 COMM_I4 COMM_I5



COMM_Q2 COMM_Q3

COMM_I6 COMM_I7



 

 



I7 



Q6  Q7 







COMM_I3 COMM_Q0 COMM_Q1

COMM_Q7 COMM_I4 COMM_I5



COMM_Q2 COMM_Q3

COMM_I6 COMM_I7



 

 



ST1_OUT3 ST1_IN0 ST1_IN1 ST1_IN2 ST1_IN3

ST1_COMM_I0 ST1_COMM_I1 ST1_COMM_I2 ST1_COMM_I3 ST1_COMM_Q0 ST1_COMM_Q1 ST1_COMM_Q2 ST1_COMM_Q3

The prepared default communication links for a small MPS ® 500-FMS system; only working position 1 of the transport system is allocated

Note

The transport system station has the communication interface shown for each working position. The working position is identical to the stopper position. PLC input I5 of the individual stations must not be used for communication transfer. Input I5 is coupled to the EMERGENCYSTOP and indicates whether or not EMERGENCY-STOP is available>. A 1-signal is applied at input 15 if EMERGENCY-STOP is not actuated.


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PLC inputs/outputs COMM_I0 to COMM_I7, COMM_Q0 to COMM_Q7, ST1_COMM_I0 to ST1_COMM_I3, ST1_COMM_Q0 to ST1_COMM_Q3 are only available for communication for the virtual MPS® stations. Real MPS® stations do not have these input/outputs as standard for communication. A description of the communication interfaces between all the stations of an MPS® 500-FMS system and therefore also of the prepared default communication links can be found in CIROS® Advanced Mechatronics Assistant. The tables show the allocation of the symbolic PLC addresses used for communication to the absolute PLC addresses.


Testing station


Symbolic

Absolute

Symbolic

Absolute

Symbolic

Absolute

address

address

addresse

address

address

address

IP_FI

I0.7

IP_FI

I0.7

IP_N_FO

Q0.7

I4

I1.4

I4

I1.4

ST1_IN0

I2.0

I5

I1.5

I5

I1.5

ST1_IN1

I2.1

I6

I1.6

I6

I1.6

ST1_IN2

I2.2

I7

I1.7

I7

I1.7

ST1_IN3

I2.3

Q4

Q1.4

Q4

Q1.4

ST1_OUT0

Q2.0

Q5

Q1.5

Q5

Q1.5

ST1_OUT 1

Q2.1

Q6

Q1.6

Q6

Q1.6

ST1_OUT 2

Q2.2

Q7

Q1.7

Q7

Q1.7

ST1_OUT 3

Q2.3

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Testing station


Symbolic address

Absolute address

Symbolic address

Absolute address

Symbolic address

Absolute address

COMM_I0

I2.0

COMM_I0

I2.0

ST1_COMM_I0

I2.4

COMM_I1

I2.1

COMM_I1

I2.1

ST1_COMM_I1

I2.5

COMM_I2

I2.2

COMM_I2

I2.2

ST1_COMM_I2

I2.6

COMM_I3

I2.3

COMM_I3

I2.3

ST1_COMM_I3

I2.7

COMM_I4

I2.4

COMM_I4

I2.4

ST1_COMM_Q0

Q2.4

COMM_I5

I2.5

COMM_I5

I2.5

ST1_COMM_Q1

Q2.5

COMM_I6

I2.6

COMM_I6

I2.6

ST1_COMM_Q2

Q2.6

COMM_I7

I2.7

COMM_I7

I2.7

ST1_COMM_Q3

Q2.7

COMM_Q0

Q2.0

COMM_Q0

Q2.0

COMM_Q1

Q2.1

COMM_Q1

Q2.1

COMM_Q2

Q2.2

COMM_Q2

Q2.2

COMM_Q3

Q2.3

COMM_Q3

Q2.3

COMM_Q4

Q2.4

COMM_Q4

Q2.4

COMM_Q5

Q2.5

COMM_Q5

Q2.5

COMM_Q6

Q2.6

COMM_Q6

Q2.6

COMM_Q7

Q2.7

COMM_Q7

Q2.7

Allocation of symbolic PLC addresses to the absolute PLC addresses for a number of MPS ® 500-FMS stations


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Note

The transport system station has the communication interface shown for each of the six working positions. The name of the communication variable includes a reference to the working position for the purpose of differentiation. The working position is identical to the stopper position. The communication variable for working position 2, i.e. the processing working position, starts with ST2_. These variables do of course have a different absolute address than the variable starting with ST1_. You will find the complete list of the communication variables of the transport system station in CIROS® Advanced Mechatronics Assistant.

Display of communication links

Communication links are created and displayed in the Manual Operation window. The status of a communication link is identified by the graphic representation of the connection.

Process Activities are displayed in the lefthand part of the window. These are the variables to which the process model simulation reacts. You can change the value of these variables in that you can for example apply 1-signal at a communication input or a valve coil. The righthand part of the window shows the process activities. These are the variables which adjust the simulation of the process model. The user cannot change the value of these variables. Examples of process activities are sensor signals or also the values of communication outputs.

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Communication links are shown in the middle section. Communication links form part of the I/O connections. The signal flow of a communication links runs from right to left. You can see this by the orientation of the arrow at the end of the links. The status of a communication link can be identified by the colour of the links: Blue: Link is selected, Red: Link has the value 0, Green:


Link has the value 1.

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This is how you establish the prepared default communication links ®

1. Make sure that®the desired MPS is loaded. The example selected shows an MPS 500-FMS system. This system consists of a transport system, the distributing and testing stations in the form of product input and the handling and sorting stations in the form of product output.

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2. Check whether the communication links have already been established via the coupling of PLC inputs and outputs. To do so, open the Manual Operation window by activating the Manual Operation command in the Modeling window.

3. If the middle section of the window with the heading I/O Connections is not displayed, then open the context-sensitive menu via the right mouse button. You open the context-sensitive menu by moving the mouse pointer into the Manual Operation window and then pressing the right mouse button. Select the command Show I/O connections.


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4. Double click the + symbol in front of the individual stations in the

Manual Operation window to display the entries regarding all the stations and, insofar as available, also the communication links. No communication links are displayed in the I/O Connections window. Therefore, no communication links are established. They have been deleted by the user at an earlier stage.

5. To create the prepared default communication links activate the Create Communication Links command in the Modeling menu under I/O Confiuration.

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6. The communication links are set up and shown in the Manual

Operation window under I/O Connections in the form of graphic connections between the respective communication input/outputs.

7. You can now simulate the running of the prepared PLC programs.

Note

In the case of MPS® 500-FMS systems the default communication links used are already created automatically via I/O connection during the modelling. Provided that you do not make any changes to the PLC programs and the communication interfaces, you do not need to create the communication links. With MPS® Standard systems the prepared communication links are not automatically created via I/O connection. If you want to realise multi-bit communication for MPS ® Standard systems via I/O connection and use the prepared communication links for this, you need to create the communication links using the described menu commands.


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This is how you delete the default communication links ®

1. Make sure that the desired MPS system is loaded. The selected example shows an MPS® 500-FMS system. The system consist of a transport system, the distributing and testing stations in the form of product input and the handling and sorting stations as product output.

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2. Activate the Delete Communication Links command under I/O

Configuration in the Modeling menu. 3. All default communication links are now deleted. You can establish this in the Manual Operation window in the I/O Connections section. Connections are displayed neither between the communication inputs/outputs of the distributing and testing stations nor between the communication input/outputs of the testing and transport system stations. The same applies for the product output and transport system stations.

Note

The Delete Communication links command deletes all default communication links. This command does not delete user-defined communication links. Delete individual communication connections with the command Remove I/O Connection in the context sensitive menu for the manual operation window.


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This is how you create user-defined communication links

You can create or delete individual communication links yourself at any time. It is however important that you use communication interfaces other than the prepared default interfaces in the PLC programs for the stations of your system or, for example, if you only want to create exactly those connections which are evaluated by the PLC programs. 1. Load the desired MPS® system. The selected example displays an MPS® Standard system, which consists of the distributing, testing and sorting stations.

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2. Open the Manual Operation window by clicking onto the Manual

Operation command in the Modeling menu. This window is divided into three parts. If the middle part of the window with the heading I/O Connections is not shown, then open the context-sensitive menu via the right mouse button. Open the context-sensitive menu by moving the mouse pointer into the Manual Operation window and then pressing the right mouse button. Select the Show I/O Connections command.

3. Double click the + Symbol in front of the stations to display all entries regarding the stations. No connections are shown between the communication inputs and outputs of the stations. Consequently, none of the communication links for the system have been created as yet.


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4. You require a connection between the PLC output Q4

Communication of the testing station and the PLC input I6 Communication of the distributing station. 5. In the righthand section of the window scroll down the items of the testing station into the viewable area of the window. On the lefthand side of the window scroll down the items of the distributing station into the viewable section.

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6. To establish the desired connection, click onto the Q4 Communication line of the testing station. The line is now highlighted. Move the mouse pointer onto the blue double arrow next to the highlighted entry. The mouse pointer now changes into a rectangle with connection lines. You can now establish the connections. Press the left mouse button and whilst holding down the left mouse button, move the mouse pointer to the arrow next to the entry I6 Communication of the distributing station. Then release the mouse button again. The communication link has now been created.

7. If you now click onto Q4 Communication of the testing station, the entry 16 Communication of the distributing station connected to this output is automatically highlighted.


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8. Next, you want to establish a connection between the PLC input I4

Communication of the testing station and the PLC output Q6 Communication of the distributing station. 9. You now need to select the desired output Q6 Communication of the distributing station in the righthand window under Process Status. On the lefthand side of the window then scroll the 14 Communication entry of the testing station into the viewable section of the window.

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10. To establish the desired connection, click onto the entry Q6

Communication of the distributing station. The entry is now highlighted. Then move the mouse pointer onto the blue double arrow next to the highlighted entry. The mouse pointer now changes into a rectangle with connecting lines. You can now establish the connection. Press the left mouse button and, whilst holding down the mouse button, move the mouse pointer up to the arrow next to the 14 Communication entry of the testing station, then release the mouse button again. The communication link is now set up.

11. Proceed in the same way if you require further communication links between the stations of your system.


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This is how you delete user-defined communication links ®

1. Load®the desired MPS system. The example selected displays an MPS Standard system, which consists of the distributing, testing and sorting stations.

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2. Open the Manual Operation window by clicking onto the Manual

Operation command in the Modeling menu. If the middle section of the window with the heading I/O Connections is not displayed, then open the context-sensitive menu via the right mouse button. To do so, move the mouse pointer into the Manual Operation window and then press the right mouse button. Now select the Show I/O Connections command.

3. Double click the + symbol of the individual stations to display the entries for the stations.


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4. Click onto the entry, whose connection you want to delete. In this exampIe, this is the I4 Communication entry of the testing station. If you want to see the communication output with which 14 Communication is connected, then scroll down in the righthand section of the window until the connection is fully displayed.

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5. Click onto the I4 Communication entry of the testing station again or onto the associated entry Q6 Communication of the distributing

station. Open the context-sensitive menu via the right mouse button and select the Remove IO Connection command.

6. The communication link has been deleted.


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4.5 Simulating a system

The production run of the system can be simulated as soon as a system is modelled and the necessary communication links are set up.

The following preconditions must be fulfilled for MPS® Standard systems: The stations must be correctly positioned next to each other and connected. If the stations are correctly positioned, then the position and alignment of the StationLink sensor which transmit the communication signal are also correct. The communication links are thus correctly established.

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A PLC program which controls the operation of the station must be available for each station. The PLC program can be executed either via the internal S7 PLC or an external controller. If you are using the default settings of the software, then the sample PLC program of the station is automatically loaded to the internal S7 PLC and executed when simulation is started. If no PLC program is active, then the user can systematically control individual process components of the system by using the manual operation window functions.

Note

The user can disconnect the connection between station models and PLC selectively in order to manually control individual process components.

The prerequisites for MPS® 500-FMS systems are as follows: The stations must be correctly positioned and aligned with the transport system. The communication links between the PLC inputs and outputs of the stations must be established. This is effected automatically for the prepared communication links as a result of the correct positioning and alignment of the stations on the transport system. A PLC program must be available for each station, which controls the operation of the station. The PLC program can be executed either via the internal S7 PLC or an external controller. If you are using the default settings of the software, then the sample PLC program of the station is automatically loaded to the internal S7 PLC and executed. If no PLC program is active, then the user can selectively control individual process components of the system using the manual operation window functions. If you simulate a system that is incorrectly configured, the individual process components will behave differently during simulation than expected.


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As soon as system simulation is active, you can monitor the visual simulation and therefore the production sequence of the system in the activity window. Certain information is always available to you. The file name and path data of the loaded system are shown in the header line. The status bar informs you regarding the operating status of the system: A field to the right displays whether simulation is active or stopped. Stopped: The simulation mode is not active. The system is not

Cycle:

being simulated Not simulated. The system is being simulated.

Running:

The system is being simulated.

The field on the left indicates the simulation time.

Note

In CIROS® Advanced Mechatronics the two simulation modes Cycle and Running are identical.

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This is how simulation is switched on and off again

1. Make sure that the system is in the initial position by executing the Reset Workcell command in the Simulation menu. 2. Activate the Start command in the Simulation menu. The simulation is active. You can identify the simulation mode in the status line via the Running entry. Alternatively you can also activate simulation via the Start Cycle menu entry or via the Stopped button in the status bar.

3. To stop simulation, click Stop in the Simulation menu. Alternatively you also click onto the Running field in the status bar.


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As soon as simulation is active, you can operate and monitor the system.

Note

Proceed as follows if you want to save a modelled system after simulation is executed: First activate the command Reset Workcell in the Simulation menu. The system moves into the initial position. All workpieces are removed. Then activate the required command to save the system.

4.6 Operating and monitoring a system

If system simulation is active, you can operate each station controlled via the sample PLC program using the pushbuttons and switches of the corresponding control console. You can identify the status of simulation on the status bar.

Process module

Control console of MPS Standard station

Control console of transport system station

I4

I5 St a r t

St op

Re s e t

Au t o / Ma n

Q4

Q5

GND Q1

Q2

I/O

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Depending on the system combination, different production processes are executed. Pneumatic cylinders or measuring instruments can be produced. The individual production processes require different workpieces. Missing parts are designated for individual stations.

Workpieces

Suitable for systems with

Correct workpieces: Basic cylinder body of different types

Processing station Storage station Buffer station

Black

Red

Testing station Robot station Robot assembly station

Metal

Sorting station Separating station Distributing station

Workpiece of incorrect height

Processing station

and incorrectly drilled hole: Basic cylinder body

Testing station

Blue Correct workpieces:

Processing station

Housings for measuring instruments in different designs

Fluidic Muscle Press station Storage station

Black

Pick & Place station Buffer station Testing station Sorting station

Red

Separating station Distributing station

Metal


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Workpieces


Correct intermediate product: Housing for measuring

Fluidic Muscle Press Storage station

instrument with applied measuring insert in different designs

Buffer station

Black

Red Metal

Workpiece for MPS® Standard systems

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Workpieces


Correct workpieces: Basic cylinder body of different types

Distributing station Testing station

Black

Red

Processing station Handling station Quality assurance station Sorting station Robot assembly station Storage station

Metal Workpiece of incorrect height

Testing station

and incorrectly drilled hole

Blue Working with incorrectly drilled

Processing station·

hole: Housing for measuring instrument in different designs

Quality assurance station Robot assembly station

Black Red

Metal

®

Workpieces for MPS 500-FMS systems


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As soon as you create a new system, a table with the possible workpieces is displayed as standard. If simulation is active, then select the workpiece from this table which you want to use for the production process of the system.

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This is how you operate an MPS® Standard system where the individual stations are controlled via the sample PLC programs 1. Make sure that the system is in the initial position and that there are no workpiece on the stations. You realise this by activating the Reset Workcell command in the Simulation menu.

2. Start simulation by clicking the Start command in the Simulation menu. 3. The illuminated Reset button now prompts the reset function on all stations.


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4. Carry out the reset function for each station by clicking onto the

Reset button. We recommend that you carry out the resetting of the individual stations against the material flow.

5. The illuminated Start button of a station indicates that the corresponding station is now in the initial position and the start precondition is fulfilled. 6. Make sure that workpieces are available for the production process of the system. In the case of the system shown this means that the magazine of the distributing station must be filled with workpieces.

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7. Click onto the desired workpiece on the table of workpieces. All workpieces are realised in the form of buttons. The selected workpiece, a red basic cylinder body, is shown as „pressed“. Then click onto the symbolic workpiece on the distributing station.

With each mouse click the magazine is filled with the workpiece selected.

Note

Not every workpiece is suitable for every station. If you have selected a workpiece which cannot be processed by a station, this workpiece cannot not be generated for the station.


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8. Start the sequence of each station by clicking onto the Start button. This starts the automatic mode of the station. We recommend that you start the stations in the sequence in which they are arranged in the material flow.

9. With the key actuator you can choose between continuous cycle (switch position vertical) and individual cycle (switch position horizontal) for the sequence of a station. 10. You can interrupt the sequence of a station at any time by pressing the STOP button. If you want to restart the station, you need to carry out the Reset function beforehand.

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If a station is controlled via a PLC program you have created, then you will know how the running and operation of the station are defined. If a station is not controlled via a PLC program, you can selectively trigger the process actuators manually. You will need the manual

operation window functions for this.

Note

Slides filled with workpieces, which result in the production process stopping, can be emptied via appropriate commands in the manual operation window.


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This is how you operate an MPS® 500-FMS system where the individual stations are controlled via the sample PLC programs The operation of an MPS® 500-FMS system is described using the example of a fully expanded MPS ® 500-FMS system. 1. Make sure that the system is in the initial position and that there are no workpieces on the stations. This applies in particular to the pallets of the transport system station, the storage slots of the automated warehouse station and the slides of the sorting station. Remove all workpieces by activating the Reset Workcell command in the Simulation menu.

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2. Start the simulation by clicking the Start command in the Execute menu. 3. The starting of simulation causes the master switch on the system to be switched on. The master switch supplies the whole system with power. The master switch is located on the side of the control cabinet of the transport system station. 4. First, you start the transport system station. The flashing Automatic On button prompts the start function. Click onto the Automatic On button. The transport system is running and the Automatic Off button is illuminated.


135


5. In the case of the stations at the operating positions Product Input, Processing, Assembly and Product Output, the illuminated Reset button prompts the reset function.

6. Carry out the reset function for the stations mentioned by clicking onto the Reset button.

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7. In the case of the automated warehouse station it is equally mandatory to carry out the reset function. However, for reasons specific to this station, the reset sequence of the ®s automated warehouse station is different to that of the MPS stations. To reset the station, switch the AUTO/MAN key actuator into the MAN position (switch position horizontal) by clicking onto the AUTO/MAN key actuator. The flashing Reset button indicates that the station can now be reset.

8. Click onto the Reset button. The automated storage station moves into the initial position. The axis carries out reference travel and the Start button flashes when the initial position is reached.


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9. Now switch the AUTO/MAN key actuator to the AUTO switching position (switch position vertical). Automatic operation of the station can only be started in this switching position. Start the sequence of the station by clicking the Start button.

10. The illuminated Start button on the MPS® stations indicates that the corresponding stations are in the initial position and that the start precondition is fulfilled. 11. As soon as you have filled the magazine of the distributing station with workpieces, i.e. with basic cylinder bodies, the start precondition for this station is also fulfilled. The Start button is illuminated.

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12. Fill the magazine by clicking onto the desired workpiece on the workpiece table. The selected workpiece, a red basic cylinder body, is shown depressed. Then click onto the symbolic workpiece on the distributing station. With each mouse click the magazine is filled with the workpiece selected.

13. Start the sequence of each station by clicking onto the Start button. 14. With the AUTO/MAN key actuator you can choose between continuous cycle (switching position vertical) and individual cycle (switching position horizontal) for the sequence of a station.


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15. You can interrupt the sequence of a station at any time by pressing the STOP button. If you want to restart the station, you need to carry out the Reset function beforehand.

Note regarding the automated warehouse station

The automated warehouse station only participates actively in the production process if product output for the process is not or is no longer available for the process. In concrete terms this means: The automated warehouse stocks up if ‟ one or both stations of product output are not started or ‟ the slides at product output are full. The automated warehouse takes out workpieces if ‟ an empty pallet passes.

Note regarding the quality assurance station

The quality assurance station identifies the housing for a measuring instrument as a reject part. The station passes on this information to the transport system station and the transport system station passes on the information to the robot assembly station. The robot then rejects the transferred reject part.

Note

If a station is controlled via a PLC program you have created, you will know how the running and operation of the station is defined. If the station is not controlled via a PLC, you selectively trigger the process actuators manually. You will need the functions of the Manual Operation window for this. Slides filled with workpieces and which result in the production process stopping, can be emptied using appropriate commands in the Manual Operation window.

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This is how the status of an MPS ® system is indicated

LEDs on the sensors and valves indicate the electrical status of the process components. The LEDs on the inputs/outputs on the control console, provided for the I/O connection, indicate the status of the communication signals. If air is applied at a cylinder connection, the connection is highlighted in blue. The pneumatic tubing itself is not shown. In the windows Inputs and Outputs you can identify the status of the PLC signals for the station selected. The Manual Operation window provides you with an overview of all process statuses and process activities of the system and also displays all the communication links. The designation of a component is shown by clicking onto the connection or the LED of a process component. This designation is identical to the designation in the circuit diagram. One exception is the designations of the supply ports. These form part of the valves which supply the supply port with air.


141


142



Note

You can also display additional information regarding the sensors. The settings for this are effected in model explorer. Activate the command Model Explorer in the Modeling menu. A tree structure is displayed. Click onto the top entry. In the case of an MPS ® 500-FMS system, the entry is MPS® 500. Now activate the context-sensitive menu via the right mouse button and select the Properties command. The window Properties for workcell is displayed. Activate the Sensor Simulation register. In the Visualisation section click onto the two check boxes for the entries Show Measuring Range and Show Measured Value(s). Both boxes are now shown with a tick.


143


Close the Properties for workcell window. Close the Model Explorer window. The respective sensor lines are now shown in the system.

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4.7 Changing the view of a

You can freely adjust the perspective view of a modeled system. With a

system

representation of the process model.

few central commands you can rotate, move, enlarge or minimize the


145


The perspective view is defined by the coordinates of the viewer (= standpoint) and a reference point of the process model (= mid point).

Reference point

Angle

Turn

Z

Y

X

Definition of perspective view

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This is how you move the modeled system

1. Activate the Move command in the View menu. The mouse pointer now changes into a small coordinate system, which indicates the direction in which the standpoint and reference point can be moved. A dashed arrow means that it is not possible to move into the corresponding direction. 2. Hold down the left mouse button. 3. Move the mouse pointer in the Z or X direction. 4. Release the mouse pointer again. The view then changes accordingly. You can also activate the Move command by holding down the Shift key and then pressing the left mouse button.

This is how you rotate the modeled system 1. Activate the Rotate command in the View menu. The mouse pointer changes into a small coordinate system, which indicates the direction in which the standpoint and reference point can be moved. A dashed arrow means that it is not possible to move in the corresponding direction. 2. Hold down the left mouse button. 3. Move the mouse pointer in the Z or X direction. 4. Release the mouse pointer again. The view then changes accordingly. You can also activate the Rotate command by holding down the Ctrl key and then pressing the left mouse button. To tilt the system in any direction, hold down the Alt key and left mouse button and move the mouse.


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This is how you enlarge or reduce the view

1. Activate the Zoom command in the View menu. The mouse pointer changes into two squares. 2. If you want to enlarge the view, then hold down the left mouse button and move the mouse pointer in the direction of the arrow. 3. If you want to reduce the view, then hold down the left mouse button and move the mouse pointer against the direction of the arrow. You can also activate the Zoom command by holding down the key combination Shift+Ctrl and then pressing the left mouse button. If you have a mouse with a scroll wheel, you can easily enlarge or minimise the system view by using the scroll wheel.

This is how you enlarge a specific section 1. Position the mouse pointer on a corner of the section. 2. Hold down the key combination Shift+Ctrl. 3. Press the right mouse button and move the mouse. A frame is now displayed. 4. By moving the mouse, place the frame around the section you want to enlarge. 5. Release the right mouse button and the section is now enlarged.

This is how you enlarge the view Activate the Zoom-In command in the View menu. The picture is enlarged to 125%.

This is how you reduce the view Activate the Zoom-Out command in the View menu. The picture is now reduced to 80%.

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4.8 The Inputs and Outputs

The Inputs and Outputs windows show which signals are applied at the

windows

shown in red and 1 signals in green. If the input or output signal is forced, the value is shown in angle brackets, e.g. <1>.

inputs and outputs of the PLC for the selected station. 0 signals are

The PLC inputs/outputs available for communication are designated differently in MPS® Standard systems and MPS® 500-FMS systems. In MPS® Standard systems you will find Panel_I4, Panel_I6, Panel_I7, Panel_Q4, Panel_Q5, Panel_Q6, Panel_Q7 for the PLC inputs/outputs available on the control console for I/O connection. COMM_I0 … COMM_I7, COMM_Q0 … COMM_Q7 as additional inputs/outputs for I/O connection.


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In MPS® 500-FMS systems for example, PLC inputs/outputs of the transport system station have an identifier, whereby PLC inputs/outputs can be allocated to the individual stopper positions.

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This is how you open the Inputs window

1. Make sure that the desired system is loaded and simulation is active.


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2. Select the station whose PLC inputs you wish to observe. To do so, click onto the Controller Selectionin the Programming menu. Select the desired PLC in the Current column via a mouse click.

Note

The Controller Selectionwindow displays all the stations of the modelled system which have their own internal controller. The controllers are switched to active by default. If system simulation is started, for example via the Start command in the Simulation menu, then the PLC programs of the active controllers are started in sequence4. If system simulation is stopped, the execution of the PLC programs in the active controllers is also stopped. The status as to whether or not a PLC is operating is shown in the Start/Stop column.

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The status of PLC inputs/outputs is displayed in the Inputs/Outputs window only for the controller selected as Current. Also, PLC programs can be loaded to the selected internal controller. To do so, use for example the Open command in the File menu.

3. Activate Inputs/Outputs in the View menu and select Show Inputs.

So that you know which process signal it is, the signal names include the relevant designations from the circuit diagrams. Example: STATION_1B2: The PLC input which is connected to sensor 1B2.


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This is how you open the Outputs window

1. Make sure that the desired system is loaded and simulation is active.

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2. Select the stations whose PLC you wish to observe by clicking onto the Controller Selection command in the Programming menu. Select the desired PLC in the Current column.

Note

The Controller Selectionwindow displays all the stations of the modelled system which have their own internal controller. The controllers are switched as active by default. If simulation of the system is started, for example via the Start command in the Simulation menu, the PLC programs of the active controllers are started in sequence. If system simulation is stopped, then the execution of the PLC programs is also stopped in the active controllers. The status as to whether or not a PLC is operating is displayed in the Start/Stop column.


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The status of PLC inputs/outputs is displayed in the Inputs/Outputs window only for the controller selected as Current. Also, PLC programs can be loaded to the selected controller. To do so, use for example the Open command in the File menu.

3. Activate Inputs/Outputs in the View menu and select Show Outputs.

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So that you know which process signal it is the signal names include the relevant designation from the circuit diagrams. Example: STATION_1M1: The PLC output which is connected to valve coil 1M1.

Note

It is of course possible to open the Inputs and Outputs windows at the same time. You can also open the Inputs and Outputs windows via Workspaces in the Windows menu, where you will find the frequently required window combinations.

4.9 The Manual Operation window

The Manual Operation window offers various functions: Display of the process statuses and process activities of a system, Controlling of individual actuators of a system, Display of communication links realised via I/O connection, Creating of user defined communication links via I/O connection, Setting of stops in the simulation of a system. The entries for the individual stations of a system are configured in a tree structure. By double clicking onto the + symbol of a station, all entries are displayed regarding the respective station. A double click onto the minus symbol hides the entries again.


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The lefthand section of the window displays the process activities. These include primarily the actuation of valves and the controlling of communication inputs. 1 signals are indicated by a red illuminated LED. Process activities are variables to which the process model simulation reacts. As the user, you can change the value of this variable. You can monitor all process activities in the righthand section of the window. The process statuses include status of sensors, valve coils and communication outputs. Here, 1 signals are indicated by a green illuminated LED. Process statuses are variables that are set and correspondingly displayed by the process model simulation. The user cannot change the value of these variables. The status of signals is also shown in the Value column. If the signal is forced, the value is shown in angled brackets. You can show or hide the display of the Value column. You will find the relevant command in the context-sensitive menu via the right mouse button.

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Additional information is also displayed: If the signal status has changed since the last simulation cycle, the relevant line is highlighted in colour. This enables you to easily identify and follow the signals that have last changed. If the Value Change is not shown in colour, then activate Show Value Changes in the context-sensitive menu via the right mouse button.

Communication links are shown in the middle section of the window. Communication links form part of the I/O connections.


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The signal flow of a communication link runs from right to left. You can see this by the orientation of the arrows at the connection ends. You can identify the status of a communication link by the colour marking of the connection: Blue: Red: Green:

Connection is selected, Connection has the value 0, Connection has the value 1.

By clicking onto an entry for which a communication link exists, the respective communication user is also shown highlighted. If the middle section of the window headed I/O Connections is not displayed, then activate Show I/O Connections in the context-sensitive menu via the right mouse button.

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Additional information

I/O connections are connections between the inputs and outputs of the

regarding the I/O

system.

connections

Differentiation should be made between PLC inputs and outputs on the controller side, Process inputs and outputs on the process side. PLC outputs, for example the signal for a valve coil, are input signals for the process. Conversely the process generates output signals, for example sensor signals, which are then connected to a PLC input. These connections between PLC inputs/outputs and process inputs/outputs also form part of the I/O connections and are required internally by CIROS® Advanced Mechatronics. They are taken into account in the Manual Operation window, but are not fully displayed. The Manual Operation window is used solely to manage the communication links realised via I/O connection. The table below provides an overview of the meaning of the symbols by the entries in the window section I/O Connections.


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Symbol Process inputs

Meaning Not connected Connected, but with output not displayed Connected with displayed output Inverted connection with one displayed output Forced to the value 0

Process outputs

Not connected Connected, but with input not displayed Connected with one or several displayed outputs

Important

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You may only delete those I/O connections, which you have created yourself as communication links. Otherwise it may no longer be possible to simulate the system correctly.



This is how you open the Manual Operation window

1. Make sure that the desired system is loaded. The example selected shows an MPS Standard system, which is made up of the distributing, testing and sorting stations.


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2. Activate Manual Operation in the Modeling menu. Alternatively, open the window by activating Manual Operation under

Workspaces in the Windows menu.

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3. Now double click the + symbol of those stations whose process statuses and process activities you want to monitor or control. The example shows the process statuses and process activities for the distributing station.

Note

You can show or hide the middle section of the Manual Operation window headed I/O Connections as required. To do so, activate or deactivate the Show I/O Connections command in the context-sensitive menu via the right mouse button.


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This is how you control individual actuators of a system

If you want to manually actuate individual actuators of a system or selectively set communication signals, we recommend that you disconnect the respective stations of the system from their controllers. In this way only the commands triggered via manual operation will be executed. The PLC programs are no longer active. This procedure prevents the output of conflicting commands to process components. You may however also want or need to intervene manually in the running of a station controlled via a PLC program. This enables you to correct faulty process signals so that the sequence of a process continues to be executed. Or you can „simulate“ communication signals of neighbouring stations and therefore test and commission individual PLC programs.

If you want to terminate manual operation and the respective station or selected stations are to be controlled via the PLC programs again, then reconnected the system with controller of the stations again. 1. Make sure that simulation is stopped. 2. Open the Manual Operation window by activating Manual

Operation in the Modeling menu.

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3. Disconnect the system from the controllers. Move the mouse pointer into the left section of the Manual

Operation window to the process activities. Press the right mouse button to open a context-sensitive menu and select the Disconnect All Controllers command.

Note

You can of course also disconnect the controller from just one station. To do so, highlight the required station in the Process Activity section of the Manual Operation window. Then open the context-sensitive menu via the right mouse button and select the Disconnect Selected

Controllers command.


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4. Start the simulation. 5. Double click the line of the process activity you wish to execute. The double click causes the value of the signal to change. If you double click a line with a valve actuation, then the value of the corresponding valve coil changes. If the value 0 applies, this is set to 1 and vice versa. The double click therefore has a toggle function. Please note: To switch a valve with two valve coils into a specific switching position, the appropriate signal must be applied at both valve coils.

6. Stop the simulation if you wish to terminate manual operation.

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7. To control the system via the PLC programs in the controllers again, move the mouse pointer into the left section of the Manual

Operation window to the Process Activities. Open the contextsensitive menu via the right mouse button and select the Restore I/O Connections command.

Notes

The execution of the Reset Workcell command in the Simulation menu also causes the inputs/outputs of the system to be reconnected to the inputs/outputs of the controllers.


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This is how you set the stops in the operation of a system

If you want to stop the operation of a system at a defined point, then you need to set stops within the simulation of the system. You can stop the execution of a process whenever the value of a process signal changes. The stops merely influence the simulation of the system, the PLC programs for the control of the system remain unaffected. If a stop is applied to a signal, the system simulation stops if the signal value changes. The changed signal value is transmitted to the system as soon as simulation is restarted. 1. Make sure that the desired system is loaded.

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2. Start the system simulation and make sure that the system is controlled via the PLC programs. Open the Controller Selection window if the system is controlled via the sample PLC programs of the individual stations. To do so, click onto the Controller Selectioncommand in the Programming menu. By the symbol of the green arrowhead in the Start/Stop column you will see that all three controllers of the system shown are operating and the PLC programs are being executed in the controllers.


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3. Open the Manual Operation window by activating Manual

Operation in the Modeling menu. If the window is in three parts, you can hide the middle I/O Connections section since this section is not required when working with stops. To hide the I/O Connections window section, deactivate the Show I/O Connections command in the context-sensitive menu via the right mouse button.

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4. Double click the + symbol for the-example of the distributing

station to display all the process activities of this station. Now click onto the line of the required process activity, in the case of this example line 2, to control the valve coil 1M1 for the ejector slide of the magazine. Press the right mouse button to open the contextsensitive menu and select Stop at Value Change.


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5. The stop symbol in the line in the Manual Operation window indicates that a stop is set at this signal.

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6. Operate the process. As soon as the PLC of the distributing station generates a 1 signal at valve coil 1M1, simulation stops. You can follow the status of simulation at the status bar.

7. The process is continued if you restart simulation of the system. The ejecting slide of the magazine ejects a workpiece.


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8. If you want to delete the stop, click onto the line with the stop point with the right mouse button. Open the context-sensitive menu via the right mouse button and select the command Stop at Value Change. This command is realised in the form of a toggle function. The stop is removed. Alternatively you can also select the Delete All Stops command.

Note that you can also set stop at the signals in the Process Status section of the window.

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This is how you control the operation of a system step by step

Use the Manual Operation window as a tool to control the simulation if you want to execute the sequence of the process step by step. You can stop the process at defined points by setting stops. To execute the process step by step, set the stops at the process activities of a station or of several stations. With this procedure the process is stopped whenever an actuator of the respective station changes its status. If you also want to take into consideration and monitor communication signal during the step by step operation, then you need to set the stops at the corresponding signals in the window section Process Activity and Process Status. 1. Make sure that the required system is loaded. It is generally helpful if the system is in the initial position.


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2. Start simulation of the system and make sure that the system is controlled via PLC programs. You can establish the operational status of the individual controllers in the Controller Selection window.

3. Open the Manual Operation window by activating Manual Operation in the Modeling menu. 4. If the I/O connections are displayed in the Manual Operation window, then hide these.

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5. Double click the + symbol, for example of the distributing station, to display all the process activities of this station. Under Process Activity , highlight all lines which contain signals for valve coils by pressing the Ctrl key and clicking onto the desired lines with the left mouse button. Open the context-sensitive menu via the right mouse button and select Stop at Value Change.


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6. All lines with valve coils now show stops.

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7. If you also want to monitor communication, then you need to similarly set stops at the corresponding communication signals. In the case of MPS Standard systems, the communication exchange takes place via optical sensors. For the distributing station only the optical sensor IP_FI needs to be considered.

8. Operate the process using the pushbuttons and switches of the station control consoles. The simulation stops whenever the status of a process signal of the distributing station changes. The process continues to be executed when you restart the simulation.


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9. Open the context-sensitive menu via the right mouse button if you want to remove the stops again. Select the Delete All Stops entry, doing so for both window sections.

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4.10 Controlling a system

Each station is equipped with an internal PLC. A SIMATIC S7 simulator is

using the internal S7 PLC

programs.

used as internal PLC. The S7 simulator interprets executable S7

A sample PLC program for S7-300 is available for each station. When you load a station from the library, the sample PLC program is automatically loaded to the internal PLC of the respective station. Once simulation of the system is started the internal PLC executes the S program. You can of course also download a different S7 program to the internal PLC of a station. If doing so, you need to keep in mind the following: Only complete project files with the file extension S7P can be loaded. The projects must have been created with the SIMATIC Manager and conform to the Siemens MC7 code at the binary level. This is the case with all STEP-7 programs created in LDR, FCH, STL or GRAPH.


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This is how you control a station using a corresponding sample PLC program 1. Load the desired MPS system. The sample selected displays an MPS Standard system. The system is made up of the distributing, testing and sorting stations.

2. The supplied sample PLC program for each station is loaded by default to the corresponding internal PLC. 3. As soon as simulation of the system is started, the PLC programs of the individual stations are also executed. Activate Start command in the Simulation menu.

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Note

If you have modified the PLC program for a station in the corresponding internal PLC, the modified PLC program will of course be executed once simulation is started.

This is how you control a station using a newly created S7 PLC program 1. Load the desired MPS station.

2. Make sure that simulation is stopped.


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3. Select the station whose PLC program you want to modify. The PLC program is to be executed by the internal PLC. To do so, activate the Controller Selection command in the Programming menu. In the Controller Selection window click on to the required station in the Currentcolumn.

4. Select the Open command in the File menu to open the Open File window.

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5. Under file type, select S7 Project (*.S7P). All the files of this format available in the active directory are displayed.

6. Navigate to the directory which contains your S7 project. Select the required S7 project and click onto Open.


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7. If the project you have selected contains several S7 programs, select the one required for the simulation and confirm this with OK.

8. Start simulation of the system. Select the Start command in the Simulation menu. Once simulation of the system starts the PLC programs of the individual stations are also started. The newly loaded PLC program of the internal PLC is executed for the station you have selected.

Note

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Another option is also available for loading PLC programs to the internal PLC of station.



This is how you load a PLC program to an internal PLC (alternative method) 1. Make sure that the desired MPS system is loaded.

2. Make sure that simulation is stopped. 3. Open the S7 Program Managerby activating the S7 Program Manager command in the Programming menu.


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4. The just loaded PLC program for each internal PLC is shown in a clearly set out tree structure. Click onto the + symbol in front of the station whose PLC program you want to change. In the exampIe the testing station has been selected. Highlight the Program entry.

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5. Open the context-sensitive menu via the right mouse button and select the Load command.

6. The Open window is now displayed.


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7. Navigate to the directory which contains your S7 project. Select the desired S7 project and click onto the Open button.

8. If the project you have selected contains several S7 programs, select the one required for simulation. Confirm your selection with OK.

The required PLC program is loaded. You can now simulate the operation of the system.

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This is how you establish which S7 program in the internal PLC of a station has just been loaded 1. Make sure that the desired MPS system is loaded.

2. Activate the S7 Program Manager command in the Programming menu.


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3. A clearly set out tree structure shows the just loaded PLC program for each internal PLC.

4. Click onto the + symbol to display the name and structure of the PLC program. The PLC program can consist of the following modules: Organisation modules, data modules, functions and system functions.

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5. Click onto the + symbol again to display the modules of the PLC programs. You can view the contents of the module by double clicking onto a module.

Further information regarding the display of S7 programs in STL or the display and use of timing diagrams can be found in the online Help.


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This is how the sample PLC programs are filed on the computer

1. Select the Open command in the File menu. The Open File window is now displayed. 2. Select S7 Project (*.S7P)under file type. All the files of this format available in the active directory are displayed.

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3. Navigate into the directory in which you have installed the Software package CIROS® Advanced Mechatronics software package. From ®

there change to the directory \CIROS Advanced Mechatronics\bin\FD_PLC_ADV\S7 where four subdirectories are shown. ‟ The directory MPSC_V22 contains the S7 project mpsc_v22.s7p, where you will find the sample PLC programs for all MPS Standard stations. ‟ The directory FMS50__1 contains the sample PLC programs for the transport system of MPS 500-FMS systems. ‟ ‟

The directory 313C__1 contains the sample PLC programs for the individual stations of MPS 500-FMS systems. The directory Store contains the sample PLC programs for the automated warehouse station.

4. As an example, change to the directory MPSC_V22. Select the S7 project and click onto Open.


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The program name provides information about the PLC program and the station model to which it belongs: The initial digit corresponds to the station number. The two letters after the first digit indicate the station: VE: Distributing station PR: Testing station BE: Processing station HA: Handling station PU: Buffer station MO: Assembly station SO: Sorting station PP: Pick&Place station FM: Fluidic Muscle Press station TR: Separating station LA: Storage station The letters starting with underscore indicate the programming language of the PLC program: AS: The programming language GRAPH, KFA: The programming languages LDR, FCH and STL, The internal PLC supports to a large extent the command set of the S7400 controllers, whereby the programs can be created in ladder diagram, function chart, statement list or in the form of graphic sequence control.

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5. Close the window by clicking on the Cancel button.

Note

You must never modify the sample PLC programs shown here because these are the standard default programs required for the simulation of an MPS system. If you want to make changes to the PLC programs, then install these a second time using the specially provided installation command of CIROS® Advanced Mechatronics Assistant.

4.11 Controlling a system station using the external Soft PLC S7-PLCSIM

S7-PLCSIM is a soft PLC, which executes the PLC programs created in STEP 7. A wide range of different testing and diagnostic functions for fault finding in the PLC program are available within STEP 7. These testing and diagnostic functions include for example the status display of variables or the online display of the PLC program. You can use these functions if you create the PLC program for a station of a system in STEP-7 and then test the PLC program in conjunction with the simulation of the system. The exchange of PLC input/output signals between the system and the soft PLC S7-PLCSIM is effected via the EzOPC program. The EzOPC program forms part of the CIROS® Automation Suite and has been installed on your PC together with the CIROS ® Advanced Mechatronics application. EzOPC is automatically invoked by CIROS® Advanced Mechatronics as soon as you start simulation of the system. The prerequisite for starting EzOPC is of course that at least one station of the system is controlled via an external PLC.

Note

If you work with the operating system Vista, please make sure that the used S7-PLCSIM-Version is Vista compatible.


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To ensure that the exchange of PLC input/output signals with the selected station is correctly effected, the following requirements must be met: When starting EzOPC, both communication users – S7-PLCSIM and simulation of the system – must be active. Only then can EzOPC set up the communication link to both users. The EzOPC program must be correctly configured for the exchange of data. Therefore check the configuration as soon as EzOPC is started.

Configuration of EzOPC for data exchange with S7-PLCSIM

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This is how you control a station of the virtual system using S7PLCSIM 1. Start STEP 7 or then STEP 7 Manager and open the desired S7 project. 2. Start S7-PLCSIM by clicking onto the menu item Simulate Modules under Extras.


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3. The window of S7-PLCSIM is opened. Enter the input/output bytes you want to exchange and monitor.

4. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto MRES in the CPU window.

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5. Download the required PLC program to the S7-PLCSIM by highlighting the modules folder. Then activate the Download command in the PLC menu. The PLC program is to control a selected station in a virtual MPS system in CIROS® Advanced Mechatronics. The selected station to be controlled via S7-PLCSIM is the distributing station.


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6. Load the appropriate MPS system in CIROS ® Advanced Mechatronics.

7. Make the necessary setting for the desired station, i.e. that this is to be controlled via an external PLC by activating the Switch external

PLC

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internal PLC command in the Modeling menu.



8. The Switch external PLC

internal PLC window is now opened. The columns Type and Program Name/OPC Servershow the information for the controller of the selected station. As an example consider the entries for the distributing station: ‟ ‟ ‟

The name of the station is Distributing. The station is controlled via the internal PLC. You can establish this by the S7 PLC simulator entry. The internal PLC executes a PLC program, which is part of the STEP 7 project MPSC_V22.S7P with specified path.

9. Highlight the desired station via mouse click. Activate the contextsensitive menu via the right mouse button and select the Switch command. Alternatively changeover the controller by double clicking the desired station.


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10. For the selected station OPC server is now entered in the Type column. The name FestoDidactic.EzOPC.2 is now displayed under

program name/OPC server. This entry means the process signals for the selected station are exchanged via an OPC server named FestoDidactic.EzOPC.2.

11. Close the Switch external PLC

internal PLC window.

12. Check whether the system should be in the initial position. If so, activate Reset Workcell command in the Simulation menu.

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13. Start simulation of the system by activating Start in the Simulation menu. When simulation is started the EzOPC progam is automatically invoked. You can establish this by the EzOPC entry in the bar.


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Note

With the starting of system simulation, the communication program EzOPC is also started. When EzOPC is started, both communication – users - S7-PLCSIM and the simulation of the system must already be active. Only then are the communication links correctly set up.

14. Click onto EzOPC in the start bar. The EzOPC window is now displayed, where you configure the communication between CIROS® Advanced Mechatronics and S7-PLCSIM. The overview indicates that CIROS® Advanced Mechatronics is connected to S7 PLCSim via the virtual controller of EzOPC. The table shows which components are installed individually and whether EzOPC is in the process of accessing this component. Make sure that the communication links of your EzOPC are configured as shown below. The desired communication links are established by clicking onto the appropriate button.

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15. Now click onto the Virtual Controller register where the virtual controller status and your inputs/outputs are displayed. 8 input bytes and 8 output bytes are preset for data exchange. You can accept this presetting unaltered. If a 1-signal is applied to an input/output byte bit, then this is shown illuminated.


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16. Click onto the S7-PLCSIM register and check the settings. Here, the status of S7-PLCSim simulation and its inputs/outputs is displayed. 8 input bytes and 8 output bytes are preset for data exchange. You can accept this presetting unaltered. However, only the first 4 bytes are required. If a 1-signal is applied to an input/output byte bit, then this is shown illuminated.

17. Minimise the EzOPC window.

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18. Start S7-PLCSIM by clicking onto the check box next to RUN in the

CPU window. The LED for RUN should now start flashing.


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19. Operate the system. In particular, observe the behaviour of those stations for which you have created the PLC program yourself. It can be useful here to monitor the statuses of the PLC inputs and outputs for the respective station. Open the Inputs and Outputs window by activating the commands Show Inputs or Show Outputs under the Inputs/Outputs entry in the View menu.

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20. Make sure that the PLC inputs and outputs for the right station are displayed by activating the Controller Selection command in the

Programming menu. Select the controller for the desired station in the Current column. For the example this should be the distributing station.


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21. If errors still exist in the PLC program, then the online representation in STEP 7 provides excellent support during fault finding. To do so, call up the program module in which you suspect the fault. Activate the Monitor command in the Test menu. You can now monitor which PLC program sections are executed or not in parallel with the simulation of the process.

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4.12 Controlling a station of the system using the external Soft PLC CoDeSys SP PLCWinNT

CoDeSys SP PLCWinNT is a Soft PLC which executes the PLC programs created in CoDeSys. The PLC input and output signals are exchanged between the system simulation and the Soft PLC CoDeSys SP PLCWinNT via the EzOPC program. EzOPC is part of the CIROS® Automation Suite, and will have been installed on your PC together with the CIROS® Advanced Mechatronics application. CIROS® Advanced Mechatronics automatically starts up EzOPC as soon as the simulation of the system begins. Of course, at least one station of the system must be under the control of an external PLC before EzOPC can be started.

Note

If you are using the MS Windows Vista operating system, ensure that the version of CoDeSys SP PLCWinNT which you are using is Vistacompatible.


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The following requirements must be fulfilled in order to ensure that the PLC input and output signals are exchanged correctly with the selected station: There must be an interface to the OPC server EzOPC in the CoDeSys PLC program. The input and output signals of the PLC program are transferred byte by byte via this interface. The UNPACK functional module and the PACK function in CoDeSys can be used to convert bits to bytes. Program execution in CoDeSys SP PLCWinNT UNPACK (FB) EB0

B

PLC program B0 B1 B2 B3 B4

OPC_notUsed OPC_1B2 OPC_1B2 OPC_notUsed OPC_2B1 OPC_2B1 OPC_3B1 OPC_3B1 OPC_notUsed

&

B5 B6 OPC_notUsed OPC_notUsed B7

PACK (FUN) OPC_notUsed OPC_P2 OPC_P2 OPC_notUsed OPC_notUsed OPC_notUsed OPC_notUsed

B0 B1 B2 B3 B4

PACK

AB1

OPC_notUsed B5 B6 OPC_notUsed B7

EzOPC Process inputs (Sensors)

Process outputs (Actors) CIROS® Process model simulation

Simple program example of OPC interface in CoDeSys

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When starting EzOPC, both communication users – CoDeSys SP PLCWinNT and the system simulation in CIROS – must already be active. Only then can EzOPC set up the communication link to both users. The EzOPC program must be correctly configured for data exchange. In order to ensure this, check the configuration as soon as EzOPC starts up.

Configuration of EzOPC for data exchange with S7-PLCSIM


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This is how you control a station of the virtual system with CoDeSys SP PLCWinNT 1. Start CoDeSys and open the desired CoDeSys project.

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2. Make sure that the Util.lib library is entered in the Resources tab. If this is not the case, add the Util.lib library using the Library

Manager: Double-click on Library Manager in the Resources tab. In the Insert menu, select Additional Library. Find the location where Util.lib is stored. The default location for the library is in the directory c:\Program Files\3S Software\CoDeSys\Library. Once you have selected the Util.lib library, click on the Open button. Close the Library Manager window. 3. Next, define the input/output signals to be exchanged with the CIROS® process model via the OPC interface. The input/output signals in the example project can be easily identified by the extension OPC. The input/output signals are defined as global variables. You can open the Global_Variables window by opening the Global Variables folder in the Resources tab, then double-clicking on Global_Variables.


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4. Expand the control program by calling up the UNPACK functional module. This extracts the EB0 input byte and converts it into 8 Boolean variables. In the example project, only bits 1, 3 and 4 of the EB0 input byte are needed. Remember that an instance (Unpack_EB0 in the example) must be defined in the program head before a functional module can be called up. 5. Expand the control program by calling up the PACK function. The PACK function combines 8 Boolean variables into one byte. In the example, the PACK function shows the output signal OPC_P2 on bit 1 of output byte AB1.

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6. Make sure that the Soft PLC CoDeSys SP PLCWinNT is set as the target system for the project. To do this, double-click on Target

Settings in the Resources tab. 3S CoDeSys SP PLCWinNTmust be set as the configuration.

7. Next, configure the settings in CoDeSys for the data exchange between CoDeSys SP PLCWinNT and CIROS® Advanced Mechatronics. To do this, open the Start menu, go to 3S Software -> Communication and select CoDeSys OPC

Configurator.


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8. Set Single PLC for OPC communication. Do this by selecting Single

PLC in the File menu.

9. In the tree structure, click on Server and set an Update Rate of 100 for the OPC server. Alternatively, you can also use the preset value.

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10. In the tree structure, click on PLC and enter the name of the PLC project.

Note The project name must exactly match the name of the CoDeSys project file. If the project is changed, the name must also be changed here to match.


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11. In the tree structure, click on Connection to specify the type of connection between the OPC server and the Soft PLC. As both programs run on the same computer, select the Local option for Gateway. Select Tcp/lp with the Address localhost as the Device for the new connection. Configure the settings in the Communication Parameters window.

12. Open the Communication Parameters window by clicking on the Edit button. Then click on the Gateway button and select Local as the connection for Gateway.

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13. Click the New button to define the parameters for the new connection channel. Enter the name of the channel and select

Tcp/lp as the device.

14. Close the window Communication Parameters: New Channel. 15. Close the windows Communication Parameters and OPCConfig.


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16. Next, prepare the input/output bytes which are to be transferred via the OPC interface for data exchange. To do this, activate the Options command in the Project menu in CoDeSys. In the Options window, click on Symbol configuration.

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17. Select Dump symbol entries, then click on the configure symbol file button. This opens the Set object attributes window.


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18. Open the Global Variables folder and select the objects AB1 (BYTE) and EB0 (BYTE). Hold down the Ctrl key while selecting. Place a tick in each check box and close the Set object attributes and Options windows.

19. Click on the Rebuild all command in the Project menu. 20. Start CoDeSys SP PLCWinNT by selecting it from the Start menu.

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21. The CoDeSys SP PLCWinNT window opens.

22. To establish the connection between the CoDeSys programming system and the Soft PLC CoDeSys SP PLCWinNT, activate the Login command in the Online menu in CoDeSys.


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23. If the current project is different to the PLC program in the Soft PLC, you will be asked whether you wish to load the current PLC program when you log in. Click Yes. The current project is loaded into the Soft PLC.

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24. Load the corresponding MPS in CIROS ® Mechatronics.

25. Alter the settings for the desired station so it is controlled by an external PLC. To do this, go to the Modeling menu and activate the Switch external PLC internal PLC command.


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26. The Switch external PLC

internal PLC window opens. The Type and Program Name/OPC Servercolumns show information on how the selected station is controlled. For example, take a look at the entries for the Distributing station: ‟ ‟ ‟

The name of the station is S7_Distributing. The station is controlled by the internal PLC. You can see this from the S7 PLC Simulator entry in the Type column. The internal PLC executes a PLC program. The PLC program is part of the STEP 7 project MPSC_V22.S7P with the specified path.

27. Click on the desired station to highlight it. Click the right mouse mutton to open the context-sensitive menu. Select the Switch command. Alternatively, you can switch the control system by double-clicking on the desired station.

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28. The column Type now shows OPC Server for the selected station. The Program Name/OPC Servercolumn now shows the server name

FestoDidactic.EzOPC.2. This means that the process signals for the selected station are exchanged via an OPC server with the name FestoDidactic.EzOPC.2.

29. Close the Switch external PLC internal PLC window. 30. Check whether the system is meant to be in the basic setting. If so, activate the Reset Workcell order in the Simulation menu.


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31. Start the simulation of the system. To do this, open the Simulation menu and select Start. As the simulation starts, the EzOPC program is automatically opened. You can see this because EzOPC appears in the start bar.

Note

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When the system simulation starts, the EzOPC communication program also starts up. When starting EzOPC, both communication users – CoDeSys SP PLCWinNT and the system simulation – must already be active. Only if this is the case will the communication links be correctly set up.



32. Click on the EzOPC button in the Start bar. The EzOPC window opens. Here you can configure the communication between CIROS ® Advanced Mechatronics and CoDeSys SP PLCWinNT. The overview shows that CIROS ® Advanced Mechatronics is connected to CoDeSys SP PLCWinNT via the EzOPC virtual control system. The table shows details of which components are installed whether EzOPC directly accesses these components. Make sure that the communication links of your EzOPC are configured as shown below. You can create the desired communication link by clicking the corresponding button.


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33. Next, click on the Virtual Controller tab. This displays the status of the virtual controller and its I/Os. 8 input bytes and 8 output bytes are preset for data exchange. You can use this preset without modifying it. If logic 1 applies to any bit of the input/output byte, this bit is represented by a brighter colour.

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34. Click on the CoDeSys tab and check the settings. This tab shows the status of the CoDeSys SP PLCWinNT simulation and its inputs/ outputs. 8 input bytes and 8 output bytes are preset for data exchange. You can use this preset without modifying it. However, only the first 4 bytes are required. If logic 1 applies to any bit of the input/output byte, this bit is represented by a brighter colour.

35. Minimise the EzOPC window. 36. Make sure that the process model simulation is active in CIROS ® Advanced Mechatronics.


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37. Start running the PLC program in the Soft PLC. To do this, open the

Online menu and click Run. You can see the current status of the Soft PLC CoDeSys SP PLCWinNT in the CoDeSys SP PLCWinNT window.

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38. Operate the system. Pay particular attention to the behaviour of the station to which you have added the PLC program yourself. You might find it helpful to follow the statuses of the PLC inputs and outputs for the station in question. To open the Inputs and Outputs windows, go to the View menu, select Inputs/Outputs and activate the Show Inputs and Show Outputs commands.


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39. Make sure that the PLC inputs and outputs are shown to the right station. To do this, go to the Programming menu and activate the

Controller selection command. Select the control system for the desired station in the Current column. In the example, this would be the Distributing station.

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4.13 Controlling a station of

If you are creating and testing your own PLC programs we recommend

the system using an external PLC

there.

that you load the programs to an external PLC and execute them from

If you are programming in STEP 7, you can use the soft PLC S7-PLCSIM as PLC, in which case you will not require any additional hardware components. You can however also use any other control and programming system, in which case you load the PLC program to your hardware PLC. The PLC program is to control a selected station of your virtual system. The exchange of PLC input/output signals between the system simulation and your external PLC is effected via the serial or the USB interface of the PC and via the EasyPort interface. In addition the EzOPC program is involved in the exchange of process signals. The advantage of this configuration is that you can use the PLC and the programming system of your choice. Also the testing and diagnostic functions provided by the programming system for this purpose are available to you for fault finding in the PLC program. We recommend that you install the simulation software CIROS ® Advanced Mechatronics and the PLC programming system on different computers.


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Station of a system


EasyPort

PLC

Possible configuration with hardware PLC and two PCs

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You can however also select another configuration and install the two software packages on one PC. Your PC needs to be equipped with two serial interfaces or one serial and one USB interfaces if you want to use the testing and diagnostic functions of the programming system during simulation of the virtual system. You can use the following as EasyPort interface: EasyPort D16 interface box for 16 digital I/O (Pt. No. 167121) The following is required as data cable: PC data cable RS232 for EasyPort with PC to RS232 (Order No. 162305) or USB adapter RS232 for EasyPort with PC on USB (Order No. 540699) For PLC EduTrainer from Festo Didactic: I/O data cable with SysLink connectors to IEEE 488 at both ends (Pt. No. 034 031) and adapter for extension to IEEE 488, crossover (Pt. No. 167 197) For any PLC: I/O data cable with SysLink connector to IEEE 488 at one end and open cable end sleeves (Pt. No. 167 122)

Note

If you want to exchange signals of one or more than 16 process inputs/outputs between an external PLC and a virtual system in CIROS ® Advanced Mechatronics, you will need two or more EasyPort interfaces.

The EzOPC program

The EzOPC program organises the exchange of PLC input/output signals between the virtual system simulation and the external PLC. EzOPC does not access the signals of the external PLC directly but via the EasyPort interface. The EzOPC program forms part of the CIROS ® Automation Suite and has been installed on your PC in conjunction with the CIROS ® Advanced Mechatronics application. EzOPC is automatically invoked by CIROS ® Advanced Mechatronics as soon as simulation of the system starts. Prerequisite for starting EzOPC is of course that at least one station of the system is controlled via an external PLC.


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The following requirements must be fulfilled to ensure that the exchange of PLC input/output signals with the selected station is correct: When starting EzOPC, both communication users ‟ EasyPort and simulation of the system ‟ must be active. Only then can EzOPC set up the communication link with the two users. In the case of EasyPort this means that EasyPort must be connected to the PC via the serial or the USB interface and voltage must be applied to EasyPort. The EzOPC must be correctly configured for the exchange of data. Therefore check the configuration as soon as EzOPC is started.

Configuration of EzOPC for data exchange with an external PLC via EasyPort

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This is how you control a station of a virtual system using an external PLC 1. Load the desired PLC program to the external PLC. The external PLC is in the STOP operating status. 2. Connect the PC with CIROS® Advanced Mechatronics to the external PLC via the EasyPort interface. ‟ The data cable Pt. No. 162 305 connects the serial interface of the PC to the serial interface RS232 of EasyPort. If you are using the USB interface, then use the data cable of ‟ ‟ ‟

‟

Order No. 540699. The PLC input output signals for the process are applied at port 1 of EasyPort. The PLC input/output signals for the control console are transmitted via port 2. If you are using EasyPort without USB interface: Select the following setting for the DIP switches under Mode on EasyPort: 1 ON (bottom), 2 OFF, 3 OFF. If you are using EasyPort with USB interface: Make sure that address 1 is set for EasyPort. The set address can be read or changed by pressing the two arrow buttons. Simultaneously pressing both buttons stores the address and exits address mode.


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Process model

1 2 3 ON

S7 E duTrainer

EasyPort

CPU313C-2 DP

RI NG

CP343-2

SF

I N

O UT

MOD E

R S2 3 2

- 24 V+

SF

BF

0

DC5V

1

FRCE

2

RUN

3

STOP

4

0

PWR

1

APF

2

CE R

3

AUP 4

CM

PUSH

RU N

5

5

6

6

7

7

Easy Port

D16

B 20+

STOP 10+

MRES IN

OUT

SE T

A

S TATUS

SH O RT

9 0

0

8

1

1

7

2

2

6

3

3

5

4

4

4

5

5

3

6

6

2

7

7

1

INPUT OUTPUT 0

7

PO RT 1

0

3

8

15

PORT 2

B

1

Configuration with PLC EduTrainer

Note

246

The two sockets marked EMERGENCY-STOP must be bridged so that the output modules of the PLC receive the voltage supply.



Process model

1 2 3 ON

EasyPort R IN G

IN

O UT

MO D E

R S2 32

- 2 4V+

Easy Port

STATU S

D16

SH ORT

INPUT OUTPUT 0

7

PORT 1

XMA2

8

15

P ORT 2

XMG1

PLC board

Configuration with PLC board


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3. Switch on the voltage supply of EasyPort. Note that EasyPort can receive voltage supply via the PORTS. ®

4. Load the desired system in CIROS Advanced Mechatronics. One station of the system is to be controlled via an external PLC. The distributing station has been selected in the example.

5. Effect the setting for the required station which is to be controlled via an external PLC by activating the Switch external PLC internal PLC command in the Modeling menu.

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6. This opens the Switch external PLC

internal PLC window. The controller for the selected station is shown in the columns Type and Program name/OPC Server. As an example take a look at the entries for the distributing station: ‟ ‟ ‟

The name of the station is Distributing. The station is controlled via the internal PLC. You can establish this by the entry S7 SPS Simulator. The internal PLC executes the PLC program. The PLC program forms part of the STEP 7 project MPSC_V22.S7P with the path indicated.

7. Highlight the required station via a mouse click. Activate the context sensitive menu via the right mouse button and select the Switch command. Alternatively changeover the controller by clicking onto the required station.


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8. OPC Server is entered for the selected station in the Type column. FestoDidactic.EzOPC.2 is shown under Program name/OPC Server. This means that the process signals for the selected station are exchanged via an OPC server named FestoDidactic.EzOPC.2.

9. Close the Switch external PLC internal PLC window. 10. Check whether the system is to be in the initial position. If so, activate the Reset Workcell command in the Simulation menu.

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11. Start the system simulation by activating Start in the Simulation menu. With the starting of simulation, the EzOPC program is automatically invoked. You can establish this by the EzOPC entry in the start bar.


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Note

With system simulation starting, the communication program EzOPC is also started. When EzOPC is started, both communication users – – EasyPort and the simulation of the system must already be active. Only then are the communication links correctly set up.

12. Click onto EzOPC in the start bar to open the EzOPC window. Here you configure the communication between H CIROS ® Advanced Mechatronics and EasyPort.

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13. The overview shows that CIROS ® Advanced Mechatronics is connected to S7 PLCSim via the virtual controller of EzOPC. ®

You will need a communication link between CIROS Advanced Mechatronics and EasyPort. Click onto the PLC via EasyPort button to establish this.


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14. The configuration link between CIROS ® Advanced Mechatronics and EasyPort is configured. The table indicates which components are installed and whether EzOPC is currently accessing these components.

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15. Now check the range of inputs/outputs via which data exchange is to be effected in the virtual controller. To do so, click onto the

Virtual Controller register. 8 input bytes and 8 output bytes are preset for data exchange. You can accept these presettings unaltered. Only the first 4 bytes are required.


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16. Click onto the EasyPort register where the status of the connected EasyPort and its inputs and outputs are displayed. If a 1-signal is applied to an input/output byte bit, then this is shown illuminated.

17. Minimise the EzOPC window. 18. Make sure that the required PLC program is installed in the PLC. 19. Start the PLC.

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20. Operate the system and in particular observe the behaviour of the station for which you have created the PLC program, whereby it may be helpful to observe the statuses of the PLC inputs and outputs of the relevant station. Open the inputs and outputs window by activating the Show Inputs/Show Outputs command under the Inputs/Outputs entry in the View menu.


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21. Make sure that the PLC inputs and outputs for the right station are displayed. Activate the Controller Selectioncommand in the

Programming menu and select the controller for the desired station.

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4.14 Setting faults in a system

Use the Fault Setting window to set specific faults in the functional sequence of a system. Use the internal S7 PLC and the sample PLC programs provided to control the system. This ensures that any potential process malfunction is caused solely by the process components. The PLC programs operate error-free. The setting of faults is permissible for authorised persons only and the dialog for the setting of faults is therefore password protected. The default setting for the password is didactic. This password can be changed at any time. A list of possible faults is available for each modelled system. The entries for the individual stations are arranged in a tree structure. All entries for the relevant station are displayed by double clicking onto the + symbol of a station. To hide the entries again double click the minus symbol.


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The following data is required if you want to create a fault in the case of one of the listed process components: Type of fault, Start of malfunction, Duration of malfunction. Various faults can occur in the case of some components. You can select these in a selection list. The following denote: Reed switch misaligned: Reed switch is mechanically misaligned. Reed switch stuck: A 1 signal is permanently applied at the reed switch. Cable break: A 0 signal is permanently applied at the component. Short circuit: A 1 signal is permanently applied at the component. Failure: Complete component failure. Tubing faulty: Pneumatic tubing is defective, operating pressure is not achieved. Compressed air line faulty: No compressed air available. Voltage supply malfunctioning: No voltage. The time specified for the commencement of malfunction refers to the simulation period after the fault is set. The duration of malfunction is to be specified in seconds. The error statuses are effected in the simulation of the modelled system as soon as the fault simulation is active. If you exit and restart CIROS® Advanced Mechatronics, malfunction still remains active and remains active until it is deactivated in the Fault Setting window.

Note

260

Default malfunction however only becomes active if the fault simulation mode is activated.



This is how you set faults in a modelled system

1. Make sure that the system is loaded. The system is to be controlled via the internal PLC. Simulation is not active. 2. Open the Fault Setting window by activating the Fault Setting entry in the Extras menu under Fault Simulation.


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3. The dialog for the password entry is now displayed. Enter the password. Provided that you have not changed the ®

password since installing CIROS Advanced Mechatronics, the set default password is still valid. Under password, enter didactic Please note that the above password is case sensitive. Confirm the entry with OK.

4. The Fault Setting window now opens.

5. Double click the + symbol of for example the distributing station to display all the possible faults of this station.

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6. Now set a malfunction ‟ for example for the PLC input 1B1. Double click the appropriate field in the Type column. A selection list is displayed. Open this list and select the type of fault, for example cable break. The fault is to become active at the start of simulation and remain active until the fault is removed from the fault setting. No entries are therefore required in the Begin column. The duration of the fault is arbitrary. No entries are therefore required in the Duration column.


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7. The faults selected are displayed in the Status column.

8. Close the file of the modelled system in order to deactivate the teacher mode. 9. Load the system with the set faults.

264



10. Now activate the fault simulation mode by selecting Fault

Simulation in the Extras menu under Fault Simulation.


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This is how you start simulation of the system with set faults

1. Load the system with the set faults. 2. Make sure that the fault simulation mode is activated. The menu item Fault Simulation in the Extras menu under Fault Simulation must be ticked.

3. Start simulation of the system.

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4.15 Eliminating faults in a

Use the Fault Localisation window to eliminate malfunction in the

system

system is controlled via PLC programs and if the fault simulation mode is active.

Example

The MPS system viewed consists of the distributing, testing and sorting stations. The sequence of the system stops once a workpiece is ejected at the distributing station. The next step - moving the swivel arm into the magazine position - is not executed.

functional sequence of the system. Set malfunction only occurs if the

By observing and evaluating the system, you realise that voltage is applied at sensor 1B1 of the distributing station, but not at the corresponding PLC input. You therefore conclude a cable break at the PLC input 1B1.


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This is how you eliminate faults in the system

1. Make sure that the desired system is loaded. 2. Open the Fault Localisation window by clicking onto Fault

Localisation in the Execute menu.

268



3. The Fault Localisation window is now displayed.

4. Double click the + symbol of the distributing station to view all possible faults.


269


5. Double click no fault in the line PLC input 1B1 and select cable

break from the selection list. The button is illuminated in yellow. If the fault has been identified correctly, the distributing station sequence will be executed error-free in the next simulation cycle.

270



6. In the teacher mode, the Fault Localisation window is displayed as follows:

Note

If you have correctly identified and entered the fault, the sequence of the system will be executed error-free in the next simulation cycle. If the cause of the fault has not been identified correctly, the fault will continue to exist. If you have erroneously identified and entered the cause of the fault as a mechanically misaligned sensor, you have created an additional fault in the process. The fault is active as of the next simulation cycle.


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4.16 Logging error elimination

Each action in the Fault Localisation window is recorded in a log file. Authorised persons have the option of viewing the log file.

The log file contains a list of activities carried out in the fault localisation window. The entries contain the following data Date Time Correctly identified and eliminated faults are highlighted in green.

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This is how you view the log file

1. Open the fault log window by activating the Fault Log entry in the Extras menu under Fault Simulation. 2. The dialog box for the password entry is now displayed. Enter the password. The preset default password is still valid, provided that you have not changed this since installing CIROS ® Advanced Mechatronics. Enter didactic under password. Note that the password is case sensitive. Confirm your entry with OK.

3. The Fault Log window is now displayed.

Note

If you want to delete the fault log, activate the context-sensitive menu via the right mouse button and select the appropriate command.


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5. These training contents can be taught using CIROS® Advanced Mechatronics

CIROS® Advanced Mechatronics is a multimedia training aid dealing with the subject of automated systems. The examples used relate to practical applications in industry and the problem definitions are based on industrial handling sequences and are aimed at a holistic training process. With CIROS® Advanced Mechatronics you are imparting methodological and handling competence.

5.1 Training contents and training aims

CIROS® Advanced Mechatronics provides process models for different, complex sections of production systems.

Main training aims

The general training aims of CIROS® Advanced Mechatronics are to achieve the following skills To design and construct PLC controlled systems in the form of distributed systems, To specify, design and test communication between the intelligent stations of a distributed system, To create, modify and test the PLC programs for the individual stations of a distributed system or complete system, To carry out systematic fault finding as part of servicing and maintenance of distributed systems. This training aim deals with all the topics which can be addressed by means of simulated processes of distributed systems. The main focus of training is aimed at a methodical procedure.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

General training aims

The following general training aims can be derived from the main training aims: The user designs a production process in the form of a distributed process and creates the appropriate system. The user understands "intelligent units" as re-usable technological modules, whereby certain specific control functions are realised. The user selects a transport system for a system and integrates this into the system. The user familiarises himself/herself with preassembled MPS standard or MPS 500-FMS systems and understands their design and mode of operation. The user familiarises himself/herself with component based automation (object-oriented procedure during the design and construction of a system) in practice and uses this. The user specifies the communication interface between the different "intelligent units" of a distributed system. The user designs the communication of a distributed system. The user designs, modifies and tests PLC programs for individual "intelligent units". The user practises structured and modular PLC programming. The user transmits communication information to the PLC program in the form of parameters via an interface. The user incorporates, tests and observes communication information in the PLC programs of the "intelligent units". The user locates and eliminates faults in the individual "intelligent units". The user carries out systematic fault finding in complex systems.


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Significance of training

Industrial development over the last few years has been governed by an

contents in industrial

ever increasing degree of automation, more and more complex work

practice

processes and faster operational sequences. The keywords here are optimal utilisation of high investment, flexible and cost effective production. These include: High machine efficiency, Reduction in downtimes, Modularisation of systems and distributed intelligence, Optimisation of systems, Continual improvement processes. As a result of the above, completely new requirements need to be met to some extent by all those in direct contact with a system. Operators and fitters assume small maintenance tasks and eventual repairs. Maintenance technicians must be able to understand electrical and electronic control technology up to a certain level to be in a position to reach conclusions regarding mechanics, pneumatics and hydraulics. Conversely, electrical engineers require knowledge regarding pneumatic and hydraulic actuators. These changing requirements in turn also lead to new forms of collaboration. By classifying these necessary requirements, the following areas are created Technology know-how System know-how and understanding Sociocultural skills CIROS® Advanced Mechatronics enables you to develop know-how and learn skills in the areas of technology know-how and system know-how and understanding. Apart from technical knowledge, these skills also include handling and methodological competence.

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5.2 Target group

The target group for CIROS® Advanced Mechatronics includes all those whose vocational line of activity involves networking, PLC programming and the maintenance and servicing of networked systems or who require basic knowledge of these subjects. These include: Vocational training ‟ Mechatronic engineers ‟ Electronics engineers, for example specialising in automation technology Plant electronics engineers Industrial mechanics Specialist qualification in the metal and electrical engineering field ‟ ‟

Training at technical colleges and universities

5.3 Prior knowledge

The following prior knowledge is required for training and working with CIROS® Advanced Mechatronics: Basic knowledge of control technology: Structure of an automated system Basic knowledge of PLC technology: Design and mode of operation of a PLC Basic knowledge of PLC programming and handling of a PLC programming tool such as the programming system SIMATIC STEP 7 Basic knowledge of pneumatic control technology: Drives, control elements Basic knowledge of sensor technology: Limit switches, contactlessly operating proximity sensors Basic knowledge of design, wiring and tubing up of electropneumatic systems. Basic knowledge of electrotechnology: Electrical variables, the correlation and calculation thereof, DC and AC current, electrical measuring techniques Basic knowledge of how to read and interpret circuit diagrams Skills in dealing with and operating Windows programs


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5.4 Example: Allocation of

Below is a table of training aims on the subjects of system know-how,

training aims to syllabi

training aims are taken from the vocational training syllabus for mechatronics engineers, status 1999. The contents are correspondingly

PLC programming, communication and systematic fault finding. The

adapted and weighted, for example in the syllabi for electrical and electronics engineers, status 2003. The skilled trades of mechatronics or electronics engineers are two examples of how, in Germany, skilled trades are currently updated and adapted to the concept of new training areas. The tables only lists those training aims which form part of CIROS ® Advanced Mechatronics training.

278



Training content: Analysis of mode of operation and structure of a system Vocation

Training area

Mechatronics

Training area 1:

engineer

Analysing of functional correlations in mechatronic systems

Training aim Reading and using technical documentation. Mastering the procedure for analysing and documenting functional correlations. Designing and interpreting block diagrams. Reading signal flow, material flow and energy flow with the help of technical documentation.

Training area 4:

Reading basic circuits of control technology: Actuation

Examining energy and information flow in electrical, pneumatic

(pneumatic and hydraulic) of a single-acting and doubleacting cylinder, basic logic operations, protective circuits, digital circuits.

and hydraulic modules

Reading and using circuit diagrams. Familiarisation with supply units in electrics, pneumatics and hydraulics. Understanding and describing the control functions of simple control systems. Configuring a control system (block diagram). Understanding signals and measured values in control systems.

Training area 7:

Understanding and describing the structure of

Realising mechatronic subsystems

mechatronic subsystems. Understanding and evaluating the mode of operation, signal behaviour and use of components (sensors and actuators). Understanding basic circuits and the mode of operation of drives.


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Training content: Analysis of mode of operation and structure of a system Vocation

Training area

Training aim

Training area 8:

Describing the structure and signal characteristics of a

Design and construction of a mechatronic system

mechatronic system.

Training area 9: To examine the

Describing the information structure (signal structure, signal generation, signal transport) of a system.

information flow in complex mechatronic systems

Analysing the effect of changing operating conditions on the process sequence.

Setting up the connection between electrical, mechanical, pneumatic and hydraulic components. Analysing signals (binary, analogue, digital) and establishing possible error sources. Using computer-aided diagnostic methods such as testing and diagnostic functions of the programming system or bus system.

Training area 11:

Analysing mechatronic systems on the basis of technical

Commissioning, fault finding and repairs

documentation and separating the construction into function blocks.

Training area 13: Handover of mechatronic systems

Describing a mechatronic system. Drawing up operating instructions and documentation.

to customers

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Training contents: PLC programming and testing of the program Profession

Training area

Training aim

Mechatronics

Training area 7:

Understanding the design and mode of operation of a

engineer


PLC. Designing and documenting control systems for simple applications. Programming simple control processes using a PLC: Logic operations, memory functions, timers, counters. Realising the programming in one of the PLC programming languages: Ladder diagram or statement list to DIN EN 61131-3. Documenting control systems in function diagrams and function chart to DIN EN 60848.

Training area 8:

Programming of mechatronic systems in one of the

Design and construction of mechatronic systems

programming languages: Ladder diagram, function chart, statement list, sequence language. Programming operating mode sections. Programming a sequence control.

Training area 9:

Using computer-aided diagnostic methods such as

Examining the information flow in complex mechatronic

testing diagnostic functions of the programming system.

systems Training area 11:

Eliminating errors in the PLC program.



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Training contents: Communication within a system Profession

Training area

Mechatronics

Training area 9:

Describing the information structure of a system with the

engineer

Examining the information flow in complex mechatronic

help of circuit diagrams and technical documentation.

systems

Training aims

Analysing signals and establishing possible error sources. Measuring and detecting signal faults in bus systems. Understanding and realising the networking of subsystems. Understanding hierarchies of networked systems. Using computer-aided diagnostic methods such as testing and diagnostic functions of the programming system. Incorporating changes into existing documentation.

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Training content: Systematic fault finding in sys tems Profession

Training area

Training aim

Mechatronics

Training area 4:

Fault finding on simple modules with the help of

engineer

Examining the energy and information flow in electrical, pneumatic

measuring technology.

and hydraulic modules Training area 7:

Testing control systems for simple applications, e.g. by


means of signal analysis.

Training area 8:

Identifying faults by means of signal analysis at

Design and construction of mechatronic systems

interfaces, eliminating error causes.

Training area 9:

Analysing signals (binary, analogue, digital) and

Examining the information flow in complex mechatronic systems

establishing possible error sources.

Training area 11:

Understanding procedures for fault finding in electrical,


pneumatic and hydraulic systems.

Computer simulation

Using computer-aided diagnostic methods, e.g. testing and diagnostic functions of the programming system.

Carrying out malfunction analysis. Mastering and using systematic fault finding. Knowing typical error causes. Targeted use of diagnostic systems. Documentating faults. Drawing up a maintenance and repairs protocol.


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5.5 The training concept of

CIROS® Advanced Mechatronics is a motivating, multimedia training aid on the subject of automated systems.

®


The systems can be flexibly programmed to different levels of complexity. This enables you to formulate problem definitions according to the requirements and prior knowledge of trainees whereby, for example, the mode of operation of individual components can be examined. It is however also possible to concentrate on the subject and training for planning the communication in a distributed system or programming and testing the operating mode part of a system. The simulated processes have their own didactic quality: They are as practice-related and real as possible. The possibility of experimenting with process models establishes an affective link to actual systems, i.e. the actual training topic, thereby testing and consolidating knowledge. The realistic experience with simulated processes provides a new quality of knowledge: Theoretical knowledge becomes application and practice-oriented ability. CIROS® Advanced Mechatronics supports self-motivated and enquiring learning: The simulated system functions in the same way as an actual system. For example, this immediately shows trainees whether they have programmed the system sequence correctly. Similarly the effect of operational errors is apparent without causing damage to the system. This enables trainees to reach and evaluate conclusions. Trainees can obtain technical documentation regarding the system or system components according to requirement. Trainees can practise their know-how and skills on a wide variety of systems.

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What are the benefits of tuition using CIROS® Advanced Mechatronics? CIROS® Advanced Mechatronics is a PC-assisted training aid and therefore represents a different training method. Lessons can be made stimulating and motivating. Know-how and skills acquired on actual systems can be improved and consolidated using practice-related process models. Simulated processes can be used to illustrate and test situations which would be dangerous on an actual system. Efficient, practice-related and task oriented training is possible even without an actual system. A system, available only once in reality, is available in multiple forms. This increases the availability of the system for tuition. The real and virtual world of automation technology can be combined in any way and adapted to the training process required. All systems simulated in CIROS ® Advanced Mechatronics are also available in the form of actual systems. This provides ideal additions and combinations for tuition. Activities and skills which can only be acquired on actual systems should not be replaced but merely supplemented, prepared or dealt with more extensively. Simulation is a modern tool used in dealing with automated systems.

Example 1: To ensure that PLC programs and the design of a system are completed at the same time, appropriate simulation of system components or of the complete system is used to test the PLC program. Example 2: Since production systems should have as few downtimes as possible, operators and maintenance staff are often familiarised with and trained on simulated systems.


285


5.6 Training scenarios for ®


CIROS® Advanced Mechatronics can be used in many different ways for vocational and further training. Here are a few examples: ®

CIROS Advanced Mechatronics in the form of an introduction for the purpose of motivation, preparation and as a knowledge database for actual MPS systems: The user has an actual MPS system which he/she wants to understand and operate. With CIROS® Advanced Mechatronics users have the possibility of creating their actual MPS system in the form of a virtual system. With the help of this virtual system, users can familiarise themselves with the automation components and stations of their system. Information is available on the online Help and via an online Assistant. Since the control and communication of the system can be automatically generated, the user does not require any knowledge of PLC programming and networking of systems for this phase. System production can be immediately simulated and the behaviour of the system observed. In line with the user’s problem definition, one can acquire comprehensive basic knowledge

regarding electrical and pneumatic processes and the components involved or practise and improve the programming of distributed systems. CIROS® Advanced Mechatronics in the form of an introduction for the purpose of motivation and preparation on the subject of distributed automation systems: CIROS® Advanced Mechatronics can be used independently of actual systems. On the basis of a library with automation stations, the user plans and designs distributed systems of varying complexity. Typical automation stations include warehouse administration, robots, processing machines and transport systems. Information regarding the components and stations is available to the user on the online Help and via an online Assistant. Since the control and communication of the system can be automatically generated, the user does not require any knowledge of PLC programming and networking of systems. The sequence of the system can be simulated immediately and the behaviour of the system observed.

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In line with the user’s problem definition, one can acquire

comprehensive basic knowledge regarding electrical and pneumatic processes and the components involved, gain an understanding of distributed processes and practise and improve the programming of a distributed system.CIROS® Advanced Mechatronics as a tool for practising PLC programming in applications of varying complexity: CIROS® Advanced Mechatronics can be used independently of actual systems. On the basis of two libraries with automation stations, the user plans and creates simple or complex virtual systems. If the user has prior knowledge in PLC programming, he/she can change or completely recreate the PLC programs of the individual stations. As soon as the desired PLC program is available, the user can simulate the running of the system. Via the simulation, the user immediately receives feedback as to whether the sequence of the corresponding station has been correctly programmed. A major advantage is that users can use the PLC and programming system of their choice, whereby they have access to the testing and diagnostic functions of the programming system. These permit quick and effective fault finding and elimination in the generated PLC program. In the case of less practised PLC programmers, systems consisting of one station can also be created. In this way all the training contents for which only a single station is required can be taught in CIROS® Advanced Mechatronics.


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CIROS® Advanced Mechatronics as a tool for practising systematic fault finding on systems of varying complexity: ®

With CIROS Advanced Mechatronics you can create systems of varying complexity into which malfunctions can be incorporated. The task of the trainee is to detect and eliminate the malfunctions during the operation of a system. CIROS® Advanced Mechatronics supports you extensively during the identification and evaluation of the ACTUAL status of the system: LEDs on the sensors and valves indicate the electrical status of the process components. If compressed air is applied to a cylinder connection, the connection is highlighted in blue. The statuses of PLC inputs/outputs are shown in a separate window. By using a nominal/actual comparison you can isolate the location of the fault and a further systematic procedure enables you to find and eliminate the fault.

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6. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics

CIROS® Advanced Mechatronics supports you in a number of different ways with the creation, familiarisation and analysing of distributed systems. The systematic procedure you use and the knowledge you acquire can be used in any way you choose and of course also on actual systems. A system is modelled from prepared stations. Whilst the system is simulated, you can operate, observe and analyse it. The system behaviour corresponds exactly to how this is defined in the PLC programs provided for the individual stations. During simulation, the PLC programs supplied are executed by the internal controller of each of the stations. The PLC programs offer a possible sequence and possible operation of the individual stations of the system. The stations can of course also be controlled via other PLC programs created by the user.

6.1 Training aims

The following training aims can be taught with the help of CIROS ® Advanced Mechatronics: Familiarisation with and understanding of the design and mode of operation of a distributed system. Familiarisation with typical components for the realisation of automated systems: Sensors and limit switches, pneumatic valves, pneumatic linear and rotary drives, electrical DC motors, programmable logic controllers. Modelling distributed systems from intelligent stations. Operating and observing distributed systems. Networking the stations of a distributed system. Familiarisation with different production processes. Evaluating technical documentation. Researching information. Recognising the advantage of a simulated system for industrial operation.


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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

6.2 Support via CIROS® Advanced Mechatronics

CIROS® Advanced Mechatronics supports you with the following during the creation and familiarisation with distributed systems: Library with prepared stations or station combinations. The stations are intelligent, autonomous system sections which perform specific machine functions. Editor for the modelling of systems. Simulation of the modelled system in 3D representation and the execution of the sample PLC in the internal controllers of the individual stations. Windows for PLC inputs/outputs: Status display of the PLC inputs/outputs of a station. Manual Operation window: Status display of all process sequences and statuses. Manual Operation window: Manual triggering of process sequences. CIROS® Advanced Mechatronics Assistant: Makes information available online such as the description and circuit diagrams of stations.

6.3 Example: Configuration of a distributed system from MPS® Standard stations and simulating production

Exercise

Configure a system for the production of measuring instruments. The workpiece housings for measuring instruments are to be supplied via the handling station. After the assembly process, the produced measuring instruments are to be sorted. Answer the following questions: Which stations do you require for the system? In which sequence must be stations be arranged? How is the initial position of the system defined? Which workpieces are required for the production process? How does the station react if a slide is filled with workpieces on the sorting station.

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Implementation

1. Start CIROS® Advanced Mechatronics. 2. Activate the MPS® System command under New in the File menu. ®

The Create MPS System window is now displayed. 3. Select a subdirectory for the new station as storage location. Enter the file name. Select CIROS® Workcells (*.mod).under file type. Then click onto the Save button.


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4. The model of an empty system is now displayed. When a new system is created, a number of settings are carried out automatically ®

in CIROS Advanced Mechatronics: ‟ The program changes into Edit Mode, ‟ ‟ ‟

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A table with possible workpieces is made available, The view selected is Top View, The Model Libraries window is opened.



5. Create the required system using the station models from the MPS®

Stations Library. A brief description and preview of the individual models is displayed if you highlight the library entry for the model and then click onto the Details button.


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6. You will find detailed information regarding the stations in the library on the online Help in the chapter CIROS® Advanced Mechatronics. Start Help by activating the Examples and Models of CIROS® Advanced Mechatronics command in the Help menu. For example a function description and technical documentation for the station are offered.

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7. Now check which station you need for the required system and how the system is to be configured.

Result

Your investigation shows that you will need the Pick & Place and Fluidic Muscle press stations for the assembly process. In addition you will also need the handling station – adjusted for successor station and the sorting station. The stations are placed directly next to one another and are coupled via optical sensors.


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8. Now create the system. First insert the handling station. To entries are available to you for this station in the library. Since an additional station will be added to the handling station, you require the handling station – adjusted for successor station. Highlight the entry Handling – Adjusted for Successor via a mouse click. Then click the Add button. The system now consists of the handling station– adjusted for successor station model. This station is shown in green since it is still highlighted.

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9. Simply click outside of the station if you want to cancel the highlighting of the station. A coupling point is shown on both sides of the station. This indicates that the station can be connected to an additional station at this point.


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10. Now enter the Pick & Place station as an additional station.

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11. All stations are inserted at the same position of the work space. Move the newly added Pick & Place station by clicking onto the highlighted station and moving the mouse pointer to the required position whilst holding down the left mouse button.

12. The two models are positioned next to one another but are not yet connected. To ensure that working and transfer positions coincide during the production run of the system, both station models must be correspondingly aligned and connected.


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13. Now align the Pick & Place station model with the handling station

– adJusted for successor station. To do so, click onto the bottom grey shaded coupling point of the Pick & Place station. Hold down the left mouse button and drag the coupling point onto the coupling point of the handling station adjusted for successor station. The Pick & Place station is now connected to the handling station – adjusted for successor station.

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14. Now enter the Fluidic Muscle press station as the next station. This station is also shown at the predefined point in the activity window.


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15. Click onto the newly added, still highlighted station and move this up next to the Pick & Place station.

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16. Connect the Fluidic Muscle press station model to the upper, free coupling point of the Pick & Place station model. To do so click onto the lower, grey shaded coupling point of the Fluidic Muscle press station. Hold down the left mouse button and drag the coupling point to the free coupling point of the Pick & Place station.


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17. Add the sorting station as the last station. Connect the sorting

station to the Fluidic Muscle press station.

18. The system is now configured. Change into the view mode to obtain a realistic 3D representation of the system. Deactivate the Edit Mode command in the Modeling menu by clicking onto the Edit Mode command. The check mark next to the Edit Mode entry is removed.

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19. A 3D representation of your system is displayed. The representation also shows a top view.


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20. To obtain a perspective view of the 3D model, select the Standard

Views/Default Settings command in the View menu. Move, rotate and zoom into an appropriate view of your system by using the commands under View.

21. Prior to simulating production of the system, the system should be in the initial position. This is achieved by executing the Reset Workcell command in the Simulation menu. By executing this command, all the workpieces on the system are also removed.

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22. Now activate the Start command in the Simulation menu. Simulation of the system is now active. You can identify the simulation mode via the Running entry.

23. Each station has an internal PLC. The supplied sample PLC program is executed with the start of virtual system simulation. The stations can now be operated using the keys and switches of the corresponding control console. The sequence of operation is defined in the PLC program. 24. Once simulation is started, the illuminated reset button requests the reset function for all stations. The system is moved into the initial position via the reset function.


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25. To obtain information in the technical documentation regarding the initial position of the system, open the CIROS ® Advanced Mechatronics Assistant. Activate the Examples and Models of CIROS® Advanced Mechatronics command in the Help menu. Click onto the CIROS® Advanced Mechatronics entry. In the chapter MPS® Standard you will find the required information regarding the individual stations in the technical documentation.

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Result

Initial position for the handling station: Linear axis in "predecessor station" position (1B2=1) and lifting cylinder retracted (gripper up) and gripper open. Initial position for the Pick & Place station: Feed separator advanced and conveyor motor off. Mini slide up and mini slide retracted and vacuum off. Initial position for the Fluidic Muscle Press station: Linear drive retracted and rotary drive in pick-up position ("predecessor station position") and pressb up. Initial position for the sorting station: Locking device advanced and sorting gate 1 retracted and sorting gate 2 retracted and conveyor motor off.


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26. Execute the reset function for each station by clicking the reset button. We recommend that you carry out the reset of the individual stations against the material flow. In the case of this system, this means: Execute the reset mode of the

sorting station, then the reset mode of the Fluidic Muscle press station, followed by that of the Pick & Place station and finally the reset mode of the handling station.

27. The illuminated start button of a station indicates that the respective station is now in the initial position. 28. Check whether the start conditions for the individual stations are fulfilled. You will find the information for this in the technical documentation for the individual station in CIROS® Advanced Mechatronics Assistant.

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Result

Start conditions of the individual stations: Handling station: Workpiece in the workpiece holde Pick & Place station: No workpiece at conveyor start and slide with workpiece inserts filled Fluidic Muscle press: No workpiece in gripper Sorting station: No workpiece at conveyor start

29. Make sure that the workpieces necessary for the production process of the system are available: ‟ ‟

One workpiece housing at the transfer position of the handling station, At least one workpiece insert on the slide of the Pick & Place

station.


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30. To supply a workpiece to the handling station, click onto the desired workpiece on the workpiece table. For example select the red measuring instrument housing. Then click onto the symbolic workpiece of the handling station. A red measuring instrument housing is made available on the workpiece holder of the handling station.

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31. Now fill the slide of the Pick & Place station with measuring instruments by clicking onto the symbolic measuring instrument of the Pick & Place station.


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32. Start the sequence of each station by clicking onto the start button. The automatic mode of the station is started. We recommend that you start the stations in the order in which they are arranged in the material flow.

33. With the key actuator you can select either continuous cycle (switch position vertical) or individual cycle (switch position horizontal) for a station sequence. 34. The sequence of a station can be interrupted at any time by pressing the stop button. If you want to restart the station, you need to execute the reset function first.

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35. If a slide of the sorting station is filled with workpieces, the station does not accept any additional workpieces. Warning light Q1 is illuminated.


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36. Remove the workpieces by executing the appropriate command in the manual operation window. Click onto the Manual Operation command in the Modeling menu. Double click onto the + symbol in front of sorting station on the left side of the window to display all the activities of the station. Double click the Empty Slides entry.

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37. Acknowledge the removal of the workpieces by pressing the start button. The production process of the system is then continued.


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7. This is how you analyse information flow in a distributed system

The exercise is intended as an introduction to the subject of networking stations. The networking is dealt with in the form of an example using the distributing, testing and sorting stations. The PLC programs are created such that they can be used for stand alone operation of the stations. At the same time, these PLC programs also support working with the stations in a network whereby minimal information about process inputs/outputs is exchanged between the stations. In the standard version, MPS® Standard stations are coupled with optical sensors. This type of coupling is known as StationLink. Throughbeam sensor emitters and receivers are used as StationLink sensors. The StationLink emitter is mounted on the material input side of the station and the StationLink receiver on the material output side. By switching on and off the StationLink emitter, the predecessor station signals whether it is ready to accept a workpiece or occupied.

Note

In the case of the distributing station only the StationLink receiver is mounted. In the case of the sorting station, only the StationLink emitter is mounted.

The user analyses how simple communication functions and how it is realised.

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7.1 Training aims

The following training aims can be taught with the use of CIROS ® Advanced Mechatronics: Understanding simple communication between the stations of a distributed system. Realising simple communication between stations via process inputs/outputs. Incorporating simple communication into the PLC program of a station. Understanding structured, programmed PLC programs. Evaluating technical documentation. Researching information. Recognising the advantage of a simulated system for industrial operation.

7.2

Proceed step by step to analyse the networking and information flow in

Methods

a system. Each step deals with an important aspect of communication. The main aspects of communication are listed below. Questions regarding the individual aspects offer suggestions and guidance as to what you should examine and consider.


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Main aspects

Questions

Function of communication

What is the function of communication? ‟ To ensure the safe transfer of workpieces ‟ To transmit information regarding the workpieces ‟ To pass on job orders to the stations

Information that is exchanged

How does communication function? ‟ What is the meaning of the signal which the information transmits? ‟ Via which absolute address is the signal evaluated? ‟ What data type is the signal?

Realisation of communication

How is communication realised? ‟ Via the coupling of PLC inputs/outputs ‟ Via the use of a fieldbus

Components for communication

What components are used to establish communication: ‟ Direct connection of PLC inputs/outputs ‟ Optical sensors for signal transmission ‟ Communication modules in field devices

Structure of communication

How are the components assembled? What needs to be considered when connecting stations?

Connection of components

What does the connection of components look like?

Communication in PLC programs

How is communication incorporated into PLC programs? Is communication information transmitted to the relevant program sections via global variables or via parameters?

Main aspects of communication within a system

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7.3 Support via CIROS® Advanced Mechatronics

CIROS® Advanced Mechatronics supports you as follows during the analysis of communication in distributed systems: Simulation of the modelled system in 3D representation and execution of sample PLC programs in the internal controllers of individual stations. Windows for PLC inputs/outputs: Status display of the inputs/outputs of a station. Manual operation window: Status display of all process activities and process statuses. Manual operation window: Status display of communications links. CIROS® Advanced Mechatronics Assistant: Online information such as descriptions, circuit diagrams and PLC programs of stations.

7.4 Example: Analysing information flow in a distributed MPS® Standard system

Exercise

Analyse the communication in an MPS® Standard system. Select the combination of the distributing, testing and sorting stations as the system. Consider the following questions when analysing the communication: What is the function of communication? What information is exchanged? How is communication realised? Via what components is communication established? How are the components assembled, what is to be considered when coupling the stations? What does the connection of components look like? How is communication incorporated into the PLC programs?


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Implementation

1. Start CIROS® Advanced Mechatronics. 2. Create an MPS® Standard system consisting of the distributing,

testing and sorting stations. As the distributing station is coupled with the testing station, select the station with the library entry Distributing – Adjusted for Testing in the model library.

3. Deactivate the Edit Mode as soon as the station is created. Change to View mode by clicking the Edit Mode command in the Modeling menu. The check mark next to the Edit Mode entry is removed.

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4. Close the model library and select a perspective view of the system by activating the Standard Views/Default Setting command in the

View menu. Using the command in the View menu, create the desired representation of the system.


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5. Refer to the technical documentation on the online Help to find out what functions communication realises in MPS ® Standard systems. ®

To do so, activate the Examples and Models of CIROS Advanced Mechatronics command in the Help menu. Click onto the CIROS®

Advanced Mechatronics entry. In the chapter Getting Started you will find a section about communication between stations.

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Result

The function of communication is to enable the reliable transfer of a workpiece from the distributing station to the testing station.


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6. Use the technical documentation for the two stations for information as to how communication functions: ‟ ‟

Which information is transmitted? Which data type carries the signal which transmits information?

Result

Distributingstation

Testingstation

Material flow

“Station occupied” bit

“Station occupied” = 1 means:

Testing station has no requirement. Distributing station must not output. Station occupied = 0 means: Testing station has requirement and requests a workpiece. Distributing station is permitted to output.

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7. Refer to the technical documentation for the two stations to find out what system resources the PLC uses to realise communication. ®

To do so activate the Examples and Models of CIROS Advanced Mechatronics command in the Help menu. Click onto the CIROS®

Advanced Mechatronics entry. In the chapter MPS® Standard you will find the appropriate stations and relevant technical documentation.


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Result Distributingstation

Testingstation

“Station occupied” bit

0-Signal

1-Signal

1-Signal

0-Signal

The signal is inverted at the receiving end. Information is exchanged via

Information is exchanged via

Input of the PLC

Input of the PLC

Output of the PLC

Output of the PLC


I 0.7

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Testing station “Station occupied” bit

Q 0.7



8. Refer to the technical documentation for the two stations to find out which components are used to transmit the information "Station occupied".

Result

Components of the distributing station Optical sensor: Through-beam sensor, receiver Components of the testing station Optical sensor: Through-beam sensor, emitter

9. Find out what is to be considered when coupling the stations.

Result

To ensure that the communication signal is transmitted error-free via the optical StationLink sensors, the optical sensors of the neighbouring stations must be positioned flush and directly opposite one another. This can be achieved by connecting the stations via the coupling points. 10. Refer to the technical documentation to find out where in the diagram the components for the realisation of communication are taken into account.

Result

Sheet

Column

Designation

Circuit diagram of distributing station 4

9

Sensor IP_FI, through-beam sensor, receiver

Circuit diagram of testing station 5


9

Sensor IP_N_FO, through-beam sensor, emitter

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11. Now observe the production process of the system.

Start simulation by activating Start in the Simulation menu. 12. The illuminated reset button requests the reset function on all stations.

13. Reset the individual stations agains the material flow.

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14. Make sure that the required workpieces are available for the production process of the system. Fill the magazine of the distributing station with, for example, red basic cylinder bodies. To do so, click onto the required workpiece on the workpiece table. Then click onto the symbolic workpiece on the distributing station. Each mouse click on the symbolic workpiece causes the magazine to be filled with a workpiece.


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15. Start the sequence of each station by clicking onto the start button. We recommend that you start the stations in the order in which they are arranged in the material flow.

16. Once all the workpieces have been tested and sorted, stop the simulation by clicking onto the Running field.

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17. Next observe the status of the communication variables during the production process of the system. To do so, open the Manual Operation window in the Modeling menu.

18. Hide the section of the window with the display of I/O connections as you do not need this information. Activate the context-sensitive menu via the right mouse button and deactivate the Show I/O Connections command. 19. If you merely want to observe the changes in communication signals, then set the stops at the appropriate signals. Simulation stops as soon as the relevant signal changes its value and you can observe the sequence at your leisure.


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20. Double click the + symbol in front of the distributing station in the lefthand section of the window. All the process sequences of the distributing station are now displayed. The process statuses of the testing station can be displayed in the righthand section of the window.

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21. Highlight the variable IP_N_FO station occupied of the testing station under Process Status and set a stop. Open the contextsensitive menu of the righthand mouse button and select the Stop at Value Change command. The variable IP_N_FO is marked with a STOP symbol.


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22. Open the PLC inputs window to also observe the communication signal of the distributing station. Activate the Show Inputs command under Inputs/Outputs in the View menu.

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23. Select the controller whose PLC inputs/outputs you want to observe. Click onto the Controller Selection command in the

Programming menu. In the Current column, select the controller for the distributing station as controller.

24. Start simulation of the system by clicking onto the Stopped button in the status bar.


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25. The indicator light Q1 on the control console of the distributing station indicates the workpieces are missing.

26. Fill the magazine of the distributing station with correct workpieces again. 27. Acknowledge the activity and click onto the illuminated start button.

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28. The distributing station ejects a new workpiece from the magazine and passes it on to the testing station. Simulation then stops because the Variable IP_N_FO of the testing station changes its value. The testing station signals "station occupied=1", because the station has no requirement. A workpiece is already present in the holder.

29. Restart simulation to continue the execution of the production process by clicking onto the Stopped button in the status bar.


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30. In the next simulation cycle, the signal STATION_IP_FI successor

station free of the distributing station is updated in the Inputs window. Its value is changed to 0. The distributing station must therefore not pass on a further workpiece to the testing station.

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31. The testing station now tests the current workpiece. As soon as the station has completed the process of testing and passed on the workpiece to the sorting station, it can accept a new workpiece. The testing station changes the value of the variable IP_N_FO. It now sends the signal "Station occupied=0". The signal change causes simulation to stop.

32. Restart simulation.


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33. In the next simulation cycle, the signal "station occupied" is read inverted as "successor station free" by the distributing station. It is therefore permissible for the distributing station to start output.

34. With the simulation of the system you have now analysed how communication between the distributing and testing stations functions. In the GRAFCETs for the stations you can reproduce in detail how and at which points in the PLC program communication is taken into consideration. You will find the GRAFCETs in the technical documentation for the stations.

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35. You can analyse the communication between the testing and sorting stations in the same way by using simulation and the technical documentation.


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Ciros Advanced Mechatronics Manual 1

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