CIROS Production Coban

7/31/2019 CIROS Production Coban

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Festo Didactic GmbH & Co. KG

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1 Basics

1. 1 Production Simulation1. 1. 1 Modeling of a new production line

New production lines are created in ProductionSimulation . Models for creation of a production line areavailable in a library. You can easily position and align a model using predefined coupling points on themodels. This way station models are aligned and connected to the transport system. The connection orcoupling points correspond to the stopper positions of the transport system.

To create new production lines use the command New Production Line in the Filemenu. This commandstarts a system editor which helps you in modeling the production line .

Note: New production lines cannot be created with the Newbutton in the toolbar.

The following example will show you how to model a production line. In a second step you will see how tosave the production line and how to switch to the view mode.


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Modeling a new production line in Production Simulation

1. Start Production Simulation. Execute theCIROS Production Simulationlink in theprogram group CIROS Productionin the startmenu of Microsoft Windows.

2. Click on New Production Line in the Filemenu.A save dialog Create a new productionlinewill appear.

3. You can use the default save folder or chooseany other folder. Enter a file name and click onthe Savebutton

4. A model of an empty production line will open. When a new production line is created, a number ofsettings are made automatically:

the program switches to Edit modeTop viewis selected as the viewthe Model Librarieswindows is opened

5. If the model library Festo FMSis not open, click on the + symbol of Festo FMS.You can findinformation, such as functional descriptions, in the online help in the chapter CIROSProduction. A short description is displayed if you select a model and click on the Morebutton in theModel Libraries windows.

6. First add the model Transport System 6. To dothis click on the entry Transport System 6andthen on the Add button.You can also add a model by double clicking onthe model entry.The production line now contains only theTransport System 6model. The model isdisplayed in green since it is still highlighted.


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7. Now add the model Station StockSinglein the same way. In older library versions you will find the entryStation Stockinstead that you may use.

8. Align the model Station StockSinglewith the transport system. For that click on the coupling point ofthe Station StockSingleand hold the left mouse button. Now move the coupling point to the top leftcoupling point of the Transport System 6and leave the mouse button.The Station StockSingleis now connected to the transport system. The position and orientation is setautomatically.

9. Add the model Station A ssembly RV-1A .10.Connect the model Station Assembly RV-1A tothe bottom left coupling point of the Transport

System 6.Click on the highlighted assembly station andhold the left mouse button. Now drag theassembly station to bottom left coupling pointof the transport system.

11.Finally add the Modell Station M ill 55andconnect it to the bottom right coupling point ofthe transport system.

As soon as your production line has been created

exit from the Edit Mode. Change to the View Modeto get a realistic 3D view of the production line.


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Changing the View Mode

1. Deactivate the command Edit Modein the Executemenu by clicking on it. The tick next to the entry EditModewill then disappear.

2. You will get a 3D view of your production line. The display will be a top view.

3. To get a perspective view of the 3D model select for example the command StandardViews -> DefaultSettingin the Viewmenu. If you use the right mouse button anywhere on the editor surface you will seethe same options as in the View -> StandardViewsmenu.

You have to save the new production line in order to create a project for a production line control systemand production simulation.

Saving a production line

1. Clickon Create plant in the Extrasmenu.This command causes the production line to besaved as a *.MOD file automatically. At thesame time a data interchange file is created.This data interchange file is required by

Production Supervisionin order to be able togenerate a project for the production controlsystem automatically.

2. The window Save plant filewill open.You can choose any directory for the XML file.But it is better to save the XML file in the samedirectory as the associated MOD file is saved.Accept the file name which is offered and clickon the Savebutton.

Note: If you want to save the production line only as MOD file without creating a XML file thenuse the Savecommand in the Filemenu.


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1. 1. 2 Changing or extending an existing production line

You can change a production line and for example add more stations.

Changing an already created production line

1. Start Production Simulationwith the link CIROS Production Simulationwhich you can find in theprogram group CIROS Productionof the start menu.

If Production Simulationalready is running make sure production in Production Supervision is stopped.Then go on with step 4.

2. To load certain production line click on Openinthe Filemenu.

3. An Open Filewindow opens. Choose the folderthe production line is saved in. Then select theMOD file Example.mod and click on Open.

4. By default the View Modeis enabled but tochange the production line the Edit Modeisneeded. Therefore activate it by clicking on

Edit Modein the Executemenu.


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5. You should reset the workcell before makingchange on a production line. The commandReset Workcellin the Editmenu will do that.

6. If you want to add another station, change theview into top view. C lick on Top Viewwhichyou can either find in the menu under View ->StandardViewsor with a right click on theeditor surface.

7. Select an appropriate view of the productionline by zooming, moving and rotating the

production line.

Note:The editing mode is exited when commandsare executed from the view menu. Make surethat the editing mode is restarted beforeadding new models.

8. Click on Model Libraries in the Modelingmenu to open the model libraries window.

9. Make the desired modifications to theproduction line, for example by adding a CNC

turn machine. Double click in the library on theentry Station Turn 55. The station will beadded.

10.Close the model library in order to see thecomplete production line.

11.Connect the new model Station Turn 55withthe right-hand coupling point of the TransportSystem 6model. Todo this click left on thecoupling point of the CNC station and drag it tothe right-hand coupling point of the transportsystem. Leave the left mouse button and the

Station Turn 55will align automatically.

12.If you wish to delete a station in the productionline then select the specific station by a leftclick. If it is highlighted in green click on it withthe right mouse button and execute the Deletecommand.


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13.Leave the editing mode after you have finishedthe modifications to the production line.Deactivate it by clicking on Edit Modein theModelingmenu.

14.Save the modified production line. Click on theSavecommand in the Filemenu.If you want to save the changed production linewith a different file name then choose SaveAs instead. A save dialog will open and youmay enter a d ifferent name.

15.In order to prepare the project for ProductionSupervisionactivate the Create plantcommandof theExtrasmenu. An XML-formatted data interchange file will begenerated.

Note: When you make modifications toa production line, the functionality of the production linewill change in most cases as well. If this is the case you must adopt the production controlsystem appropriately. If you are working with an automatically generated productioncontrol system, you must generate the entire project again in Production Supervision .


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1. 1. 3 Working with the system editorIn Production Simulationyou have a free choice of perspective view of the production line. With a fewcertain commands you can rotate, move or zoom the production line display.

The perspective view is defined by the coordinatesof the viewer (= standpoint) and a reference pointon the production line (= mid-point).


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Moving the production line

1. Activate the Movecommand in the Viewmenu. The mouse cursor will changeinto a small coordinate system. This indicates the direction in which thestandpoint and reference point can be moved. A dotted arrow indicates thatmoving in the direction concerned is not possible.

2. Hold the left mouse button.3. Move the mouse cursor in Z or X direction.4. Release the mouse button again.

The view will then change as desired.

You can also activate the Movecommand by holding down the Shift key and then pressing the left mousebutton.Rotating the production line

1. Activate the Rotatecommand in the View menu.The mouse cursor w ill change into a small coordinate system.Thisindicates the direction in which the standpoint and reference point can berotated. A dotted a rrow indicates that rotating in the direction concerned isnot possible.

2. Hold the left mouse button.3. Move it in the Z or X direction.4. Release the mouse button again.

The view will then change as desired.

You can also activate the Rotatecommand by holding down the C ontrol key and then pressing the leftmouse button.

Zooming the view in and out

1. Activate the Zoom command in the Viewmenu.The mouse cursor will change into two rectangles.

2. If you wish to make the view larger, hold down the left mouse button andmove the cursor in the direction of the arrow.

3. If you wish to make the view smaller, hold down the left mouse button andmove the mouse cursor in the opposite direction to the arrow.

You can also activate the Zoom command by holding down Shift and Control keysand then pressing the mouse button.

Zooming a certain selection

1. Position the mouse cursor on a corner of the selection.2. Hold down Shift + Control keys.


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3. Press the right mouse button and move the mouse. A frame will appear.4. Move the mouse to position the frame around the selection which you wish to enlarge. 5. Release the right mouse button. The selection will then be enlarged.


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1. 2 Production Supervision1. 2. 1 Importing a production line and generating a project

In Production Supervisionthe project for the production control system of the production line is created.The production line is modeled in the system editor of Production Simulation.

The project which is the framework for the production control system requires and manages data for thecreation and assembly of the production line. Production Supervisionreceives the necessary data fromProduction Simulationvia an XML-formatted interchange file.

As soon as data on the production line devices is available, a production system control program for asimple production line operation can be generated automatically.

In order to make working with Production Supervisionas simple as possible, work within a predefinedproject with the name Proj.


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Importing a production line from Production Simulationin Production S upervision

1. Start Production SupervisionProjectStudio inthe start menu. Use the CIROS ProductionSupervision ProjectStudiolink in the CIROSProductionprogram group.

2. An empty project called Proj.lpjwill open.You will find the default project in thesubfolder Projects\Default in the CIROSProduction\Control folder.The components in the Partstab of the Project

window have no entries for a production lineyet.

3. Activate the command Import CIROS Projectinthe Extras -> ProjectStudio menu to read theXML data file. The XML file containsinformation of the production line assembly.

4. In the open dialog you can choose which XMLfile to read. Select the XML file which isassociated to the production line loaded inProduction Simulationand click on Open.The XML file is usually saved in the same

directory as the MOD file of the production line.

5. After loading the CIROS ProductionProject a2D model of the production line is displayed inProduction Supervision.When you click on an object of the 2D display,you will see information about it in the tabPropertiesof the ProjectStudiowindow on theright.The navigation tree Partsin the Projectwindow now contains the stations andcomponents of the production line.

Note: You should never use the Savecommand just after importing anXML data file.Otherwise the empty defaultproject Proj.lpjwill be overwrittenby the imported 2D model.Therefore only use the Savecommand aftergenerating theproduction control system program.


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The production control system project at present includes only the devices for the production line. There areno programs for the production control system yet. You can see this by the navigation tree in the Project tabof the Project window. For example, the Process Plansfolder is still empty.

In orderto simulate production of the production line a program must be available for the productioncontrol system. You can automatically create the program for a simple production line sequence. Howeveryou can also program parts of the production control system yourself using process plan.

Note: Always use the Setupmodeto make changes to the production control system project.


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Generating a production control system program

1. Ensure that CIROS ProductionProjectStudiois opened with the necessary production line data.2. Activate the Setupmode. To do this, select the

Setupcommand in the Projectmenu. Only insetup mode you can generate or modify projectelements. This applies to the generation of theproduction control system program also.

3. Click on Generate projectin the Extras ->ProjectStudiomenu to generate the

production control system automatically.

4. The production control system for theproduction line has now been gene rated. Youcan see this by the new entries in the projecttree in the Projectwindow. You can ignore themessage Control elements are not yetdefined in the Messageswindow. It is meaningless in this context.

Note: The folders for Processes and Tasksare still empty since they are no static project parts.They are created in production mode as instances of executed process plans or whendevice task is started.

By default the project with the production control system is saved in the My Documentsfolder. Ensure thatProduction Supervisionproject (*.lpj) and the Production Simulation model (*.mod) are saved in differentdirectories.


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1. 2. 2 Starting or stopping the production of a production line

After a production control system has been generated you may either simulate production line operation oruse a real iCIM system.

You start and control production line operation in Production Supervision. Only then a visualization windowwill appear which offers process operations.

Note: Condition for production simulation is:Production Simulationmust be running and the appropriate productionline must be

loaded.


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Starting the production of a production line

1. Make sure that Production Simulationisopened and the appropriate production line isloaded before simulating the production line.The production line must be reset. C licktherefore on Reset Workcellin the Editmenu.

2. Start Production Supervisionand load theappropriate production control system projectby clicking on Openin the Filemenu.Choose CIROSControl P roject (*.lpj)as file

type and open the project with the Openbutton of the open dialog.If the control project doesn t exist yet you firsthave to generate it.

3. Click on Production in the Project menu tostart the production mode.When starting the production mode the controlsystem project is checked and the drivers anddevices are initialized.The initialization can take some time. Duringthat initialization time the window Startproduction will be opened which allows you to

abort the initialization or to switch toproduction immediately.

4. After initialization the visualization window willopen. This window displays the production lineand allows you to enable certain process tasks.

Production mode is started successfully only when the Visualizationwindow is completely loaded and theStart productionwindow disappears.Then you can observe carriers moving on thetransport system in the visualization window aswell as in Production Simulationor on a real iCIMsystem. The production line is ready to execute

process tasks.


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Stopping the production of a production line

1. Just closing the visualization window isn t enough to stop the production mode since it is still active inProduction Supervision. Therefore switch to Production Supervisionand click on the commandProductionin the Project menu.

2. The Stop production window will be openedwhile the deinitialization is in progress. Whilethis window is displayed, you should closeneither Production Supervisionnor FactorSimulation.

3. If your project has a process task which isrunning in the background with a loop, clickonce on the button Cancel all processes . Thiswill close the process task and continue thedeinitialization.

4. If the Stop production window won t close forsome time and closing all processes doesn thelp then use the button Abortcommunication. You should use this with care because it will kill the connection between ProductionSupervisionand Production Simulationor an iCIM system by force. Usua lly Production Supervisionwillshow some errors.Afterwards you have to reset the production line in Production Simulation . Use the Reset Workcell

command in the Editmenu of Production Simulationto do that.


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1. 3 Visualization1. 3. 1 Handling the Visualization window

There are production orders provided forA penholder (button Penholder)

A baseplate (button Baseplate)A complete desk set (button Deskset)

These are called standard strategies. To start one of the strategies just click on the appropriate button in thevisualization w indow.

When you click on the Deskset button the production control system will check whether theproduction linecontains a Station Handling & Qualityor not. If there is a quality station the base plate will be tested else itwon t.

The buttons Orders Listedand Orders Timedstart production orders from an order list which you createdbefore.

Orders in Orders Listedwill be executed one by one. Orders Timed, however, will execute orders at aparticular time.


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The order lists are created with the iCIM Production Managerwhich is activated by the Database button.

If you have programmed an own process plan and saved it with one of the default names Prod_User1,Prod_User2or Prod_User3, you can execute it in the visualization window with the appropriate buttonsUser 1, User 2or User 3.

Is a button clicked in the visualization window it will get a blue frame. This frame remains until the taskbehind the button is finished.


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Starting a production order in the Visualization window

1. Ensure that Production Supervisionis inproduction mode without errors. Then switchto the open visualization window.

2. Click on the button Desksetand the button willhave a blue frame for the duration of theprocess.You can observe the production of the deskset. You see information about executedprocess tasks or positions of the carriers.

As the current production line lacks a qualitystation the desk set is produced with anuntested base plate.

3. You can observe and analyze the production inProduction Simulationas well.

4. After the production order for the desk set isfinished you can start the production of adifferent part. Just click on another button inthe visualization window.


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1. 4 iCIM Production Manager1. 4. 1 Managing the stock contents

Three database masks are provided for stock management:

Stock Contents:In Stock Contentsyou manage the current stock contents of a warehouse. During a production of aproduct this stock is used.

Stock Init:In Stock Inityou manage the standard preset for the warehouse. These stock contents are

automatically applied to Stock Contentswhen production mode of a production line is startedforthe first time. The stock contents created by the system only contain parts with order number 0 .

Note: The standard strategies provided in the visualization window use order number 0 .

Stock User:The Stock User mask is used to create a user-defined preset for the automated warehouse. Thecontents of stock user can only contain parts with order number greater than or equal to 1 .Before the start of production you should ensure that the Stock Usercontents are loaded as thecurrent stock contentsif you want to use the stock user.

There are two variants of the automated warehouse, namely StockSingleand StockDouble. The singlestock is made up of 40 storage bins and the double stock has 88. In the database mask you can see 40

storage bins simultaneously. If you have chosen the StockDoubleyou may scroll through its contents withthe arrow buttons.


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In the 3D model of the StockDoublethe storagebins numbered 1 through 48 are located in theback row and the storage bins numbered 49through 88 are comprise the front row.

Each storage bin is identified with a locationnumber, a part number, a color code and an ordernumber.

In addition to this, each storage bin has a zonecode. The zone code considers different heightlevels of the storage bins. The user can t access the

zone code nor is it directly visible. The zone code ismanaged internally by the production database.The production database needs the zone code inorder to correctly store and withdraw parts.

The storage bins of the single stock are equivalent.All of them belong to the same zone which isidentified as Zone 0. In this zone any part can bestored independent of its geometrical dimensionsand its type of product.

As opposed to this the storage bins in the doublestock are assigned to three zones:

The storage bins numbered 57 through 64 belong to Zone 1. This is the second row from thebottom at the front section of the warehouse. These bins are low and can only take in empty palletsfor a base plate (part number 82201) or a penholder (part number 82200).

The storage bins in the top row make up an add itional zone. This zone includes the storage binsnumbered 41 through 48 and 81 through 88, and is Zone 7. High parts can be stored here forexample complete desk sets.

The remaining storage bins are in Zone 4. These can story any parts except complete desk sets.

Parts are withdrawn from the storage bin with the lowest possible number available with the appropriatepart number.

When parts are placed into storage, the lowest available storage bin number with appropriate zone code isselected.If the user enters new parts to the database they are automatically assigned to Zone 7.


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Modifying the current contents of the warehouse

1. Make sure that Production Simulationis running and the desired production line is loaded.2. Start Production SupervisionProjectStudio and

load the project with the production controlsystem of the d esired production line.

3. Start the production mode. Click in the menuProjecton the command Production.

4. After initialization of the production mod e thevisualization window is opened automatically.

5. Click on the button Databaseto open the iCIMProduction Manager.

6. Only authorized user can make changes in theproduction database. Therefore you have tologin first. Click on the Loginbutton and usethe default user Userwith the password Festo.

7. Click on the button Stock Contentsto see thecurrent contents for the production.

8. To change a storage bin click on theappropriate storage bin. Change the partnumber or the order number. Click then on thebutton Modifyto apply the changes to thecurrent stock contents.

9. You can also overwrite the contentscompletely. For this use the button Copy fromStock Userto apply the user-defined preset forthe contents.If you want to overwrite the current contentswith the default contents then use the buttonCopy from S tock Init.


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1. 4. 2 Creating order lists and producing any partsThere are two sorts of production orders:

Production orders which are executed when the relevant machines are availableProduction orders which are executed at a certain time

The order lists are created in the production database and started in the visualization window. Unlike thestandard strategies the order lists aren t l imited to fixed parts. All producible parts which are recorded in thedatabase can be produced.

Creating an order list for production orders without a definite start time

1. Make sure that Production Simulationis running and the desired production line is loaded.2. Start Production SupervisionProjectStudio and

load the project with the production controlsystem of the appropriate production line.

3. Start the production mode. Click on thecommand Productionin the Projectmenu.

4. After initialization of the production mode thevisualization window will open automatically.

5. Click on the Databasebutton to start the iCIMProduction Managerwhere you can see andedit the production database.

6. Only authorized user may modify data in theproduction database. Therefore click on theLoginbutton. If the user and password weren tchanged since the installation of CIROS Productionyou can use the default setting. As user type in Userand as password Festoand click on Login.

7. Click on the button Orders listedto open the production order list.


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8. If you want to add a new order then you haveto enter the order data in the fields belowModify Order.- The value for Working Number is enteredautomatically. You don t need to enteranything here.- Choose the pa rt number of the product whichyou want to manufacture. The possibleproducts are displayed in a selective list. Selectfor example the part number 42144 for abase plate.- Adopt the 0 for order number. This way you

can use the contents of the Stock Init.- Select a customer for this orde r. All customersmanaged in the database are shown in a list.- Choose the machine on which the productshould be manufactured. The CNC millingmachine Mill55 is offered.

9. A click on the button Add will apply the order tothe production orders list.

10.Create the data for another order.11.Add the new order to the orders list.12.If you want to change an order select it. Click in

the field of the appropriate order. The orderdata will be applied to the input fields belowModify Order.

13.Make the changes you want.14.Click on the button Modify to write the changed order back in the list.15.You can also delete single orders. Select the desired order and click on Delete current. A dialog will

appear and ask you if you want to delete the order submit it to delete the order from the l ist.


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16.After you have finished creating the order listswitch to the visualization window. Click on thebutton Orders listedto start the execution ofthe order list. The button stays framed until theprocessing of the order list is finished.

17.You can seethe state of the o rder list if youswitch back to the database window. There youcan see which production orders are currentlyactive, which are to be executed yet and whichare already completed.

Note: You can change an order only ifthe appropriate order isn texecuted by the productioncontrol system yet.

You can manufacture any producible part in the database with order lists. However a requirement is that theneeded manufacturing machine is available and the raw material is available in the warehous e.