AVI Multi State Supervisor Configuration and User Manual R1.3

AVI Multi State Supervisor Configuration and User Manual R1.3.doc

Owner: D. DeVore Page 1 of 32 Revision: 1.3

Revised: 02/28/08 PROPRIETARY Official Date: 11/18/05

Document: O:\APICS\Web Site Maintenance\Files\AVI Multi State Supervisor Configuration and User Manual R1.3.doc

APICS

AVI Multi-State Supervisor Configuration and User Manual





Proprietary Notice

This document comprises legally protected subject matter proprietary to Chrysler, and is loaned on

the basis of confidential relationship. All use and disclosure are strictly controlled. Reproduction is

prohibited without the permission of Chrysler.

Documentation Standards, Version 2.0

Copyright 2001, Chrysler. All Rights Reserved.





TABLE OF CONTENTS

1.0 INTRODUCTION................................................................................................................1

1.1 DOCUMENT PURPOSE...........................................................................................................1

1.2 INTENDED USERS .................................................................................................................1

1.3 SUPPORTING DOCUMENTATION ...........................................................................................1

1.4 TERMS & CONVENTIONS......................................................................................................2

2.0 AVI DATA FLOW OVERVIEW AND ARCHITECTURE............................................3

2.1 SETUP AND CONFIGURATION OF NEW LINKS........................................................................5

2.2 TROUBLE SHOOTING ............................................................................................................5

3.0 FIS BASED DIAGNOSIS....................................................................................................8

4.0 APPENDIX A LINK CONFIGURATION MAP FOR SUPERVISOR PLC’S [1]........9

5.0 APPENDIX B AVI MULTI-STATE SUPERVISOR LINK CONFIGURATION [2].11

6.0 APPENDIX C AVI SUPERVISOR SETUP: A CHECKLIST ......................................13

7.0 APPENDIX D SUPERVISOR MAIN ROUTINE FUCNTIONAL OVERVIEW .......14

8.0 APPENDIX E FIS INTERFACE TO PLC/5 VMS SUPERVISOR DATA

SPECIFICATION [4] ..................................................................................................................16

8.1 SUPERVISOR DATA LOCATIONS .........................................................................................17

8.2 LINK STATUS BITS (N96:4-63, STATUS WORDS 0-59) .......................................................19

8.3 SUPERVISOR STATUS BITS (N96:66, STATUS WORD 62) ....................................................19

9.0 APPENDIX F DYNAMIC DATA ALLOCATION [5-6] ...............................................20

10.0 APPENDIX G: AVI SUPERVISOR PLC SWITCHING SWI ..................................26

11.0 APPENDIX H: VERIFYING COMMUNICATIONS [6]...........................................27

12.0 REFERENCES ...............................................................................................................28





Document Revision History

Date

Revision

Number*

Name

Description (include pages affected)

11/23/05 1.0 N. Bayan First release.

11/23/05 1.1 N. Bayan Applied group input.

03/16/06 1.2 N. Bayan Added the Supervisor PLC switching procedure Appendix G.

02/28/08 1.3 A. Hanselman Changed Daimler to Chrysler logo.

* Example 1.0, 2.0, etc. Use whole numbers for major revisions (new sections, chapters, appendices) and decimal (1.1, 2.3) for minor

revisions affecting a few pages or paragraphs.




1.0 INTRODUCTION

1.1 DOCUMENT PURPOSE

This document serves as APICS, AVI Multi-State Supervisor Configuration and User

Manual.

1.2 INTENDED USERS

• Software developers, OEM or supplier integrators

• Technical writers

• Plant ITM administrator

1.3 SUPPORTING DOCUMENTATION

The Chrysler documents listed below are instrumental in configuration of mistake

proofing box. The reader of this document should read, and have a good understanding

of these documents before reading this document.

Doc. No. Title

AMS 0220. 14 Automatic Vehicle Identification document series 14.1, 14.2 and

14.3.

Specific plant ITM DCM link chart

AVI COMSPEC. 200x




1.4 TERMS & CONVENTIONS

1 Lot Refers to a quantity of one or more of the specified components as required

for the application.

A/R (As required) refers to a quantity of the specified component as required for

the application.

N/A Not Applicable

Existing Refers to equipment, old or new, that exists as referenced to the AVI

portion of this project (i.e. the equipment is not supplied explicitly for AVI

use)

Operator The term operator is used generically to describe a support person. An

operator may be production, maintenance or engineering personnel

depending on the specific application.

DCM Direct Communication Module

PFCS Plant Floor Communication Systems

AVI Automatic Vehicle Identification

APICS Automatic Product Identification and Control Systems

AME Advanced Manufacturing Engineering

PLC Programmable Logic Controller (Usually refers to AB PLC-5 series)

AB Allan-Bradley

OEM Original Equipment Manufacturer or Supplier

WCC Original Equipment Manufacturer or Supplier

e.g. Example given

i.e. id est. - that is (to say)

ca. circa / approximately

uLgx Allen Bradley’s MicroLogix 1200 Controller

CLx Allen-Bradley’s ControlLogix 5000 PLC series

CHR Chrysler

USD Universal (Unified) System Driver




2.0 AVI DATA FLOW OVERVIEW AND ARCHITECTURE

Figure 2-1 shows an overview of AVI connections and communications. AVI supervisor acts

as a front end for the AVI WCC, interfacing between plant floor controllers (mainly PLC’s)

and higher level systems.

The AVI multi-state supervisor is a message concentrator and distributor. As a message

concentrator it packages the floor messages (communicated via DCM’s) from PLC’s, and

sends those via Plant Automation network (PA) in concentrated format to AVI WCC (for

message formats refer to AVI COMSPEC 200x). As a message distributor it breaks message

packets received from the AVI WCC and redistributes them between floor PLC’s.

For detailed data allocations refer to appendix F.

AVI multi-state supervisor can handle discrete AVI drivers and USD based AVI drivers.




AVI/VMS Data Flow Diagram

READER

MainframePFS & Broadcast

File Server forOffice Automation

AVI/VMSWork CellController

AVI/VMS

SupervisorPLC

Plant FloorProcess

PLC

Plant FloorProcessOperator

HMI

Bar codeReader

3 Supervisor PLC's have 1isolated PA connection

each and support 180Process PLC's

Volume is approx 640 tpsNOTE: Volume represents

max transactions between

WCC and all PLCSupervisors.

RIO 115k baud

RS422 9.6k baudRIO 115k baud

Each Process PLC can

support a Maximum of 10points

Max packet size 256 bytesVolume is approx 1.2 tps

NOTE: This volume is

communicated over DCMcables.

Work Cell Controller has 2

OA and 1 PA connections Volume approx 1800 tps

NOTE: These are internal

transactions, fromapplication to application.

PA E-Net 10MGb

OA E-Net 10MGb

Each Workstation Client

has 1 OA connection. 512workstations supported.

Volume approx 1590 tps.

NOTE: Volume of 1590 tpsis during paint inventory

screen refresh

Mainframe has multiple

socket connections tosupport WCC.

Volume approx 5-25 tps

NOTE: 25 tps is duringdatabase recovery, or

vehicle edit cycle.

4 sec max

<1 sec normal

1 sec max<.2 sec normal

Manual product/vehicle

identification or operatoracknkowledge

Process equipmentproduct information

(Routing, Style, etc)

Vehicle/product

identification

Request for

product/vehicle information or update

Reply with

product/vehicleinformation

Request for

product/vehicle information or update

(Multipacket)

Reply withproduct/vehicle

information

(Multipacket)

Request for information,database updates

and subscriptions

Reply to information

request, andsubscription updates

Load applicationfiles from server

Reply to product/vehicle

information requestsand unsolicited updates

Request for product/vehicle information and unsolicited

updates

Workstation PCAVI/VMS Client

application

05/10/2001

Figure 2-1 AVI System Architecture




2.1 SETUP AND CONFIGURATION OF NEW LINKS

Use appendices A to C to configure links between AVI supervisor and floor PLC-5

processors. Note that USD and discrete drivers are configured in different memory

areas.

Appendix A should be used for organizing and arranging DCM link circuits in each

shop (i.e. Body, Paint and TCF).

Appendix B instructs the integrator on how to configure the links and appendix C is a

heuristic list for configuration efforts.

2.2 TROUBLE SHOOTING

Note: All floor related problems (i.e. No-Reads, Reader problem, …) shall be

corrected locally on the floor PLC’s and no change to AVI supervisor is needed.

The logic in AVI multi-state supervisor as a communication link is designed to be self-

resetting; meaning, upon sensing problems on any link, the logic retries sending the

same message and after three tries announces the link as faulty. However the system

does not disable the link and retries it during normal scans and if the link is active

again restores the communication.

Factory information system (FIS) is used for fault/alarm enunciation. Refer to

appendix E for announced FIS messages.

Figure 2-2 schematically shows points of failure (PoF) associated with AVI

supervisor.

1. PLC and Ethernet sidecar

2. AUI connector (Ethernet RJ 45 / Sub-D 15)

3. PLC to network connection

4. Plant automation network

5. AVI WCC to PA network connection

6. AVI WCC

7. DCM link to plant floor processors

8. Plant floor controllers (PLC 5)

(Note: although our goal is to indicate most probable failure scenarios, this is NOT an

all inclusive list of failures associated with AVI Supervisor system. Users should apply

common sense and best practices in trouble shooting such failures.)

For a functioning system using the FIS messages for trouble shooting is more efficient

(refer to chapter 3).




PA Ethernet

AVI WCC

AVI Supervisor

2

AVI Floor PLCs

1

3

45

6

1

7

8

LEGEND:

Possible point of failure

DCM Link Daisy Chain

Figure 2-2 Presenting points of failure (PoF) for AVI supervisor and PLC 5 platform (not applicable to ControlLogix platform)

Other than user errors, in general, problems associated with the AVI multi-state

supervisors are categorized in three categories:

• Up-link problems

• Supervisor internal logic problems

• Down-link problems

These are described and diagnosed here.

2.2.1 Up-link problems

These are usually any physical or network related problems associated with

Plant Automation network (PA). Like any other Ethernet based network the

problems associated with the connection to the AVI WCC could range between

bad cable and misconfiguration to network associated problems.




2.2.2 Supervisor internal logic problems

This logic has been successfully running in (almost) all North American

assembly plants of Chrysler without any problems associated with it. In case

there are any problems they are usually associated with peripherals such as

DCM cards, AUI connectors … The most frequent problem in the category has

been misconfiguration of the links.

2.2.3 Down-link problems

Daisy chain connection of DCM links or misconfiguration of floor PLC’s has

been the most frequent problems historically reported in this category.




3.0 FIS BASED DIAGNOSIS

The following table is an attempt to identify root causes of FIS messages related to AVI

Supervisor. For FIS messages details refer to Appendix E FIS Interface to PLC/5 VMS

Supervisor Data Specification [4].

Msg

*

F/A

**

FIS Message

Probable Root Cause Remarks

For Links ^

1 F Not Active The link is not active, the enabled bit

is not high (i.e. value is not a binary

one, 1).

Possible root cause is user

misconfiguration.

Refer to Appendix C AVI

Supervisor setup: A checklist.

PoF ^^ : 1, 7, 8.

2 F BTX Error Check proper values in configuration

area, physical connection, and

link/comm. Channel scan list.

PoF : 1, 7, 8.

Force initialization of reported link.

3 F Timeout Link block transfer time out. PoF : 7, 8.

Force initialization of reported link.

4 F Floor PLC Output Buffer

Full

Floor is re-syncing with the

supervisor. (this should NOT occur

as safe buffering is not allowed)

PoF : 8.

If not cleared initialize the floor PLC

AVI Driver.

5 F Output Buffer to Floor

Full

See if comm. is OK between

Supervisor and floor

If not cleared after 3 minutes,

initialize the AVI Supervisor link.

6 F Packet Seq. Error From

Floor

Floor is not in-sync with the

Supervisor.

Re-initialize the floor PLC AVI logic

if this is not cleared.

For Supervisor

993 F Workcell Link Timeout

Comm Lost

Message transfer instruction time

out.

PoF: 1, 2, 3, 4, 5, 6.

994 F Supervisor in Re-Sync

Mode

Supervisor IP address setup.

After loss of comm. With AVI WCC

supervisor is sending the

accumulated data to WCC.

PoF: 1, 6. If not cleared after 3

minutes, initialize the AVI

Supervisor.

* msg = Message number

** F = Fault; A = Alarm.

^ For link FIS Message description/designation refer to Appendix E.

^^ Probable Points of failure (PoF) as per Figure 2-2.




4.0 APPENDIX A LINK CONFIGURATION MAP FOR SUPERVISOR PLC’S [1]

Nxx:3 Nxx:12

Link Rack Group Value To WCC

1 1 0 32 101 Value= Word 3 in Nxx file for link.

2 1 2 36 102 To WCC = Word 12 in Nxx file for link

3 1 4 40 103

4 1 6 44 104

5 2 0 64 105

6 2 2 68 106 All values are the same in Body,Pnt, and

7 2 4 72 107 Trim except "To WCC".

8 2 6 76 108 Body: "To WCC" = 101,102,etc

9 3 0 96 109 Pnt: "To WCC" = 201,202,etc

10 3 2 100 110 Trim: "To WCC" = 301,302,etc

11 3 4 104 111

12 3 6 108 112

13 4 0 128 113

14 4 2 132 114

15 4 4 136 115

16 4 6 140 116

17 5 0 160 117

18 5 2 164 118

19 5 4 168 119

20 5 6 172 120

21 6 0 192 121

22 6 2 196 122

23 6 4 200 123

24 6 6 204 124

25 7 0 224 125

26 7 2 228 126

27 7 4 232 127

28 7 6 236 128

29 10 0 256 129

30 10 2 260 130

31 10 4 264 131

32 10 6 268 132

33 11 0 288 133

34 11 2 292 134

35 11 4 296 135

36 11 6 300 136

37 12 0 320 137

38 12 2 324 138

39 12 4 328 139

40 12 6 332 140

41 13 0 352 141

42 13 2 356 142

43 13 4 360 143

44 13 6 364 144

45 14 0 384 145

46 14 2 388 146

47 14 4 392 147

48 14 6 396 148

49 15 0 416 149

50 15 2 420 150

51 15 4 424 151

52 15 6 428 152

53 16 0 448 153




54 16 2 452 154

55 16 4 456 155

56 16 6 460 156

57 17 0 480 157

58 17 2 484 158

59 17 4 488 159

60 17 6 492 160




5.0 APPENDIX B AVI MULTI-STATE SUPERVISOR LINK CONFIGURATION [2]

1. Pick a file for the new link. The file must be the next file not used in the in the link file section

(files N11:0 thru N70:0). N11-N70 are for Block Transfer and USD. FILES N51:0-N65:0 are the

dedicated files that are used if a discrete link is being added. Because of the nature of the discrete

links, certain files have been preprogrammed to handle each instance. Discrete links cannot be

assigned to rack numbers greater then 17. The following table shows the Discrete Rack and the

associated Data Table file that must be adhered to:

Discrete Rack Data Table File Discrete Rack Data Table File

01 N51:0-499 10 N58:0-499

02 N52:0-499 11 N59:0-499

03 N53:0-499 12 N60:0-499

04 N54:0-499 13 N61:0-499

05 N55:0-499 14 N62:0-499

06 N56:0-499 15 N63:0-499

07 N57:0-499 16 N64:0-499

17 N65:0-499

Again, these files can be used for USD or Block Transfer floor drivers, but the Discrete Floor

Drivers (if any) must use these files.

2. Set N10:___ word that corresponds with the file number picked for the new link file to 500.

Example N34: file was picked for the new link in N10:34 this word would be set to 500.

3. Make the memory for the new file (create Nxx:599) if it does not exist.

4. Set word #2 in the new file with the length of the block transfer. (32). Discrete transfers (8).

5. Set word #3 in the new file with the R.G.S. value from the link chart.

6. Set word #6 in the new file with the link timeout preset (in milliseconds). (Bramalea & JNAP are 3000).

7. Set word #9 in the new file to 300. For number of free words in the buffer to the floor.

8. Set word #10 in the new file to 200. For the load pointer.

9. Set word #11 in the new file to 200. For the unload pointer.




10. Word #12 in the new file is the link # to the WCC. This number is the link # plus 100, 200 or 300

depending on which Supervisor. Supervisor #1 (usually BIW) is 100, #2 (Paint) is 200 and #3

(Assembly) is 300. The link number is calculated in the program based on the R. G. S.

assignment.

11. Set word #13 in the new file to 0-3 0=USD, 1=Block Transfer, 2= MultiBlock, 3=Discrete

12. Zero out output words from O:010 – O:177 via the data table.

13. Set bit 0 in word 0 on to enable link. Then set bit 2 in word 0 to initialize the link.

Note: Verify there are no resident links beyond the ones in the DCM chart. Zero out word zero of any

link file (Example: N14:0=0 if N14 is not a valid link) that should not exist per the DCM chart.

Troubleshooting tip-When adding or reconfiguring a link causes the processor to fault out:

1. Reconfigure the link (steps 1-11)

2. Zero out all words in the link file after word 13.

3. Reinitialize the link (steps 12-13).




6.0 APPENDIX C AVI SUPERVISOR SETUP: A CHECKLIST

USD will be used instead of Discrete (in most cases) , therefore set the following values (For

the latest DCM channel Link Chart").

Description PLC Data

File/Value

Example

Color Booth C1

(AVI Pt#2400)

Fill in for your

application

Fill in for your

application

Supervisor Used N/A PLC#3/CH 2A

New Supervisor N/A PLC#3/CH 2A

Name C1MIS

Location C141

1. Value of "xx" Used in N10:xx

and Nxx:--)

22

2. Setup file lengths N10:xx 500

3. Create Nxx:599

4. Block transfer length Nxx:2 32

5. RGS value Nxx:3 03/0, 1/4

6. Time out Preset (mS) Nxx:6 3000

7. No of free words in

buffer to floor

Nxx:9 300

8. Load pointer Nxx:10 200

9. Unload pointer Nxx:11 200

10. Link# + 200 (paint) Nxx:12 222

11. Format Type USD=0 Nxx:13 0

12. Via data table O:010-O:177 zero out

13. Enable Nxx:0/0 1

14. Initialize Nxx:0/2 1

15. Check for resident

links beyond DCM

chart (non-related

ones)

Nzz:0 0




7.0 APPENDIX D SUPERVISOR MAIN ROUTINE FUCNTIONAL OVERVIEW




File: LAD 2

Definition: AVI Multi State SupervisorMain, Functional Flow Chart

Start

First scan? OR

Init Sup link to

WCC?

N74:0/1= T?S:1/15 = T?

Yes

No

Legend:

Very Important Bit VIB

Very Important Word VIW

Very Important File VIF

Off-page Connector

On-page Connector

Jump to Label Instruction

1

Q102:100

A

Set the running bit: OTL B78:0/2

Set hardcoded Sup Link No. (MOV 100,

200 or 300 into N74:20)

IF FIS is not enabled goto end of Lad 2 if

not run FIS Driver

end

Jump to Subroutine U:13 (Initialize/Reset subroutine)

Input Parameter#1: What to do?0= First Scan Init and Reset Link Buffer

1= Reset Link Buffer

2= ?

Input Parameter#2: Link File No. (Valid range 11-70 Oct)

I have observed only zeros

1. Set Watchdog timer (S:28) to 5000mS

2. Set fault routine file (S:29) to ladder file 6

3. Zero out (reset) control queues for block transfer R&W.

4. Set Main Control Pgms (MCP) to be 2,3,4 and 5 respectively.(S:80, S83, S:86,

S89)

5. Reset all active (configured) links status bits (in Word 0 of each file). The

configured links are the ones which their associated config lengths are set to 500

or more (in file N10:xx, where xx corresponds to valid size of data file Nxx)6. Reset (zero out) output data file #N77 to WCC to the configured length (N10:77)

7. Reset (put -1) the output buffer file #N75 except the first 20 words.

VIW: N75:1 Out put buffer to WCC load pointer (set to 20)

VIW: N75:2 Out put buffer to WCC unload pointer (set to 20)

VIW: N75:3 Length of data in Out put buffer to WCC (set to 500-20=480)

VIW: N75:20 start of output buffer data

IMPORTANT NOTES:

1. General links configurations is performed in data

file N10 and there's a one on one correspondence

between links data files N11, N12, ... and N10 words

for setting up the files lengths. (i.e. N10:11, N10:12,

...) also data files N51-N55 are used for discrete

drivers.

2. Both Discrete and USD links shall be configured in

sequence. If there are any gaps (config words of less

than 500) it'll stop the driver and from that point on itwill not be initiated.

3. B78/xx refers to routine executing bits, e.g. B78/13

is for subroutine 13 executing.




8.0 APPENDIX E FIS INTERFACE TO PLC/5 VMS SUPERVISOR DATA SPECIFICATION [4]

From file “FIS VMS Supervisor.doc”

PLC/5 VMS Supervisor FIS data resides in datafile N96. This block of data is 84 words long.




8.1 SUPERVISOR DATA LOCATIONS

Word Type Description AVI PLC Address

00 Blank Spare

01 Blank Spare

02 Blank Spare

03 Blank Spare

04 Status_00 Link # x01 N11:0










































x =

Area N

um

ber (i.e. B

IW =

1, P

NT

= 2

, AS

M =

3)




8.1.1 Supervisor Data Locations (cont.)

Word Type Description AVI PLC Address



















64 Status_60 Spare

65 Status_61 Spare

66 Status_62 Area Supervisor N74:0

67 Status_63 Spare

68 Prod_cnt_0 Total number of Blocks sent to WCC

69 Prod_cnt_1 Total number of floor transactions processed

70 Prod_cnt_2 Total number of errors sent to WCC

71 Prod_cnt_3 Spare Reserved for Future





76 Acc_Cnt_0 # of floor transactions sent in last block sent to WCC

77 Acc_Cnt_1 Last WCC response time

78 Acc_Cnt_2 Time since last block sent to WCC

79 Acc_Cnt_3 Spare Reserved for Future





x =

Area N

um

ber (i.e. B

IW =

1, P

NT

= 2

, AS

M =

3)




8.2 LINK STATUS BITS (N96:4-63, STATUS WORDS 0-59)

FIS

Msg# Bit State Code Description AVI PLC Address

0 00 ALARM Spare Reserved for Future

1 01 FAULTED Link #x01 not Active Nxx:00/01

2 02 FAULTED Link #x01 BTX Error Nxx:00/03

3 03 FAULTED Link #x01 Timeout Nxx:00/10

4 04 FAULTED Link #x01 Floor PLC Output Buffer Full Nxx:00/12

5 05 FAULTED Link #x01 Output Buffer to Floor Full Nxx:00/14

6 06 FAULTED Link #x01 Packet Seq. Error From Floor Nxx:00/15










8.3 SUPERVISOR STATUS BITS (N96:66, STATUS WORD 62)

FIS

Msg# Bit State Code Description AVI PLC Address


993 01 FAULTED Workcell Link Timeout Comm Lost N74:0/00

994 02 FAULTED Supervisor in Re-Sync Mode N74:0/02,03














xx

= 1

1 to

70




9.0 APPENDIX F DYNAMIC DATA ALLOCATION [5-6]



















10.0 APPENDIX G: AVI SUPERVISOR PLC SWITCHING SWI




11.0 APPENDIX H: VERIFYING COMMUNICATIONS [6]

Use ping to verify communication.

SSttaarrtt

Ping 127.0.0.1 (Loopback Address)

Ping IP Address of a Default Gateway 33

Ping IP Address of a Remote Host 44

Ping Your IP Address 22

11




12.0 REFERENCES

[1] Excel document: SUP_LINK.XLS, Location : O:\dev\1705\avi.dev\DOCUMENT\PLC\PLC_Supervisor_Multistate

[2] Word document: “Supervisor_config_multistate.doc”, ibid.

[3] Word document: “FIS VMS Supervisor.doc” , source : ibid.

[4] Excel document: “multsupv.xls”, source : ibid.

[5] Excel document: “multi state translation.xls”, source : ibid.

[6] From Rockwell Automation presentation: “04_Enet_implementing.ppt”, source : ibid.

Documents

AVI Multi State Supervisor Configuration and User Manual R1.3