Festo

© Festo Didactic GmbH & Co. • MPS 1

FMS50 Conveyor

MPS 2000

Trainee Edition

Order no.:

Description: Mechatronics Teachware FMS50 Conveyor MPS 2000

Designation: Trainee Edition

Status: 03/2004

Author: Wolfgang Eckart, Intercon-Asia

Graphicss: Wolfgang Eckart, Festo Didactic GmbH & Co

Layout: Festo Didactic GmbH & Co

© Festo Didactic GmbH & Co., D-73770 Denkendorf, 2004

Internet: www.festo.com/didactic

e-mail: [email protected]

All rights reserved, including translation rights. No part of this publication may be reproduced or

transmitted in any form or by any means, electronic, mechanical, photocopying, or otherwise, without

the prior written permission of Festo Didactic.


Table of Contents _______________________________________________________ 1

Introduction____________________________________________________________ 4

What is Mechatronics _________________________________________________ 4

Project overview _____________________________________________________ 7

Theory of Actuator Sensor Interface – AS-I________________________________ 9

General informations on Fieldbus-systems ______________________________10

Hierarchy levels of communication systems _____________________________11

Short description of important Fieldbus-systems _________________________13

Actuator Sensor Interface – AS-I _______________________________________14

Actuator Sensor Interface – AS-I _______________________________________15

AS-I –basic components ______________________________________________16

AS-I – additional energy ______________________________________________16

AS-I – run of communication __________________________________________17

AS-I – data transfer and transmission security____________________________18

AS-I – economical installation _________________________________________20

AS-I – connection example with slaves 4 bit, 8 bit_________________________21

AS-I – input/output connection to the slave M12 (4 bit) and clamp (8 bit) _____22

AS-I – input/output connection to the pneumatic valve interface ____________24

AS-I – slave addressing with programming and service device ______________26

AS-I – slave addressing with addressing device __________________________27

AS-I – absolute hardwareaddresses within the S7 PLC program _____________29

AS-I – peripheral addresses regarding the slave address ___________________31

Table of Contents

Table of Contents

2 © Festo Didactic GmbH & Co. • MPS

Frequency converter – general informations _____________________________33

Commissioning ________________________________________________________44

1.1 Analysis – Components identification__________________________44

1.2 Analysis – Emergency Stop system ____________________________46

1.3 Analysis – Input and Output adresses __________________________49

1.4 Analysis – Input and Output adresses expanded _________________55

1.5 Commissioning – Adjustment of the Station_____________________61

1.6 Commissioning – Adjustment of the Station expanded ____________63

1.7 Commissioning – Download Project and Test ___________________71

1.7.1 Commissioning – Driver Control ______________________________76

1.7.2 Commissioning – Online check of the Driver Control______________84

Programming__________________________________________________________88

2.1 Programming – Hardware-configuration ________________________88

2.1.1 Programming – Transfer of the peripheral AS-I-adresses within OB1102

2.2 Programming – Basics in Digital Technology – AND ______________107

2.3 Programming – Basics in Digital Technology – OR _______________123

2.4 Programming – Basics in Digital Technology – RS-Flip-Flop _______127

2.5 Programming – Basics in Digital Technology – AND NOT__________131

2.6 Programming – Basics in Digital Technology – IDENTITY__________134

2.7 Programming – Condition Call of a Program ____________________137

2.8 Programming – Condition Call of a Program expanded ___________140

2.9 Programming – On-Delay-Timer function ______________________142


2.10 Programming – Off-Delay-Timer function ______________________146

2.11 Programming – Counter Down function________________________148

2.12 Programming – Programming of a Flashlight ___________________150

2.13 Programming –Programming of a Auto/Manu sequence__________152

2.14 Programming – Conveyor movement__________________________154

2.15 Programming – Conveyor movement expanded _________________156

2.16 Project – Basics of I/O– communication _______________________159

2.17 Project – Test the I/O– communication ________________________163

2.18 Project – Communication via Profibus-DP _____________________166

Trouble Shooting _____________________________________________________200

3.1 Program – Trouble Shooting_________________________________200

3.2 Process – Trouble Shooting _________________________________229


Mechatronics is a comprehensive combination of Technologies and is mostly mentioned as a new way of thinking and learning and not as a “stand-alone” technology.

The technological part of Mechatronics could be called Automation Technology.

Structure of Mechatronics

The structure of Mechatronical training is devided into three levels:

What is Mechatronics

Introduction

Introduction


The Basic Training in the single technologies is another part of training. In the following you will see some examples of the different levels:

Totally Integrated System

Partly Integrated Systems

Basic Technologies

Introduction


Basically in Automation and Mechatronics training, the contents should cover the following learning steps, or functions within a company:

Commissioning: Analyse a system, Installation&Commissioning

Programming: Programming single Station, Communication with other Stations

Trouble Shooting: Programming Errors, Trouble Shooting in the Process

which are covered within the following projects.

Furtheron this Teachware is based on the idea of a Flexible Manufacturing System – FMS, this means, this conveyor is connected to other stations, called Connection Stations within this Teachware.

Introduction


The following table give you an overview about all projects within this documentation in the structure of:

Commissioning: Analysis (Analyse a system) and

Commissioning (Installation&Commissioning)

Programming: Programming (Programming single Station and Project (Communication with other Stations)

Trouble Shooting: Program (Programming Errors) and Process (Trouble Shooting in the Process)

Project overview

Introduction


Project overview Commissioning and Programming

Learning Step Designation Project Description Proj.. Page

Commissioning Analysis Components identification: description of the function of some components used within the stations

1.1 42

Commissioning Analysis Emergency Stop system: define and identificate the Emergency Stop system

1.2 42

Commissioning Analysis In-and Output adresses of the PLC: find out the hardwareadresses of in- and outputs in the technical docum.

1.3 47

Commissioning Analysis In-and Output adresses of the PLC expanded: find out the hardwareadresses of in- and outputs in the technical docum.

1.4 53

Commissioning Commissioning Adjustment of the Station: check the adjustment all sensors and mechanical components

1.5 59

Commissioning Commissioning Adjustment of the Station expanded: check the adjustment all sensors and mechanical components

1.6 61

Commissioning Commissioning Download Project and Test: download all project-programs and test the function of the FMS-system

1.7 69

Programming Programming Hardwareconfiguration of the PLC: define the existing Siemens S7-300 PLC-hardware with the software STEP 7

2.1 86

Programming Programming Basics in digital technology–AND: programming of the basic function AND

2.2 105

Programming Programming Basics in digital technology–OR: programming of the basic function OR

2.3 121

Programming Programming Basics in digital technology–RS-Flip-Flop: programming of the basic function RS-Flip-Flop

2.4 125

Programming Programming Basics in digital technology–AND NOT: programming of the basic function AND NOT

2.5 129

Programming Programming Basics in digital technology–IDENTITY: programming of the basic function IDENTITY

2.6 132

Programming Programming Condition Call of a Program: activate a program in OB1 by a condition of the Control Panel

2.7 135

Programming Programming Condition Call of a Program expanded: activate a program in OB1 by a condition of the Control Panel

2.8 138

Programming Programming ON-Delay-Timer: programming of a ON-delay timer function using the Control Panel

2.9 140

Programming Programming OFF-Delay-Timer: programming of a OFF-delay timer function using the Control Panel

2.10 144

Programming Programming Counter down: programming of a Counter down function using the Control Panel

2.11 146

Programming Programming Programming of one flashlight: programming a flashlight with 500 ms on/off as long as a button is pressed

2.12 148

Programming Programming Programming of a Auto/Manu-sequence: program starts with Start-button/continues by Start or Auto/Manu-switch

2.13 150

Programming Programming Conveyor movement: edit a program to move the conveyor to station 6

2.14 152

Programming Programming Conveyor movement expanded: expanded program to move the conveyor to station 6

2.15 154

Programming Project Theory Basics of I/O-communication: example of different in-/output communications using different controllers

2.16 157

Programming Project Test the I/O-communication: edit a program to test the I/O-communication at the stations

2.17 161

Programming Project Communication via Profibus-DP: 1-bit bidirectional communication between conveyor and one MPS-station

2.18 164

Trouble Shooting Program Error in Project 2.2 – 2.13 time for each approx. 3.1 198

Trouble Shooting Process Maintenance Trouble Shooting 14 Process-Errors time for each approx. 3.2 227

Introduction


To offer the opportunity to get the know-how of all levels of industrial networking, the conveyor systems inputs and outputs are wired via the Fieldbus-system AS-I (Actuator Sensor Interface) which represents the basic level of networking – the sensor/actuator or field level.

In the following, please find some helpful informations about AS-I to be able to understand the basics of this fieldbus system

Theory of Actuator Sensor Interface – AS-I

Introduction


Nowadays, in complex systems with big amounts of input/output signals, it is no more practicable to realize automation tasks by only one central controller.Industrial practice shows, that it is senseful to distribute the tasks on several small automation devices. These are co-ordinated by faster controllers or Master PCs and integrated into the entire process by a bus system.

Also inputs and outputs are not longer connected directly to central signal modules of the PLC. They are connected de-centralized to I/O-terminals within the process, which are part of a fieldbus network with different controllers.

The summaries of a network are:

• Information (data) are transferred in a row over a two-wire cable (bus) • Information interchange of all participants are enabled by logical connections • Connection of all sensors and actuators to a master controller • Interconnection of equivalent controllers • Connection of all process-oriented devices to a master controller • Continuous evaluation of functionality of network participants

Network advantages:

• Flexible system construction, a plant may be easily expanded by connecting new participants

• Less commissioning than with conventional wiring • Centralized data processing and process data acquisition, new data may be

slipped into the process immediately • Higher dataset available • Less sources of error because of less wiring expediture • Centralized error control, therefore less downtime/higher operational reliability • Less service costs

General informations on Fieldbus-systems

Introduction


In order to handle the complex flow of information within big companies, there are to be formed several hierarchy levels within the automated areas.The flow of information is spread within as well as between the different levels, which means, in vertical and in horizontal direction.

Each hierarchy level has an additional level, which is setting the requirements for communication. Because the various communication tasks cannot be executed by one network, there have been developed different communication systems.

In the higher levels, there are complex computer systems. In domination are big data sets with uncritical times of response, big amounts of participants and a wide extension of networks.

Communication of the lower levels is performing less data sets and a high data processing as well as less amount of participants. Here the tasks are requirements of real time, the extension of network is mostly small.

Hierarchy levels of communication systems

Introduction


The following hierarchy levels are to distinguish:

• The evaluation of information from the manufacturing process, order planning and maintaining of guidelines and strategies for the production, is done in the planning level. Here, big data sets are being transferred over big distances within longer periods of time.

• The coordination of different production areas is done in the process level. Here, the cell level is provided by order- and program data, and it is decided, how to execute production. This is the level of the process control computers as well as the computers for projecting, diagnosis operation and protocolling.

• The cell level is connecting the several manufacturing cells, which are controlled by cell computers or PLCs. Their task is purposeful communication between intelligent systems.

• In the field level, there are programable devices for controlling, adjusting and supervising like PLCs or industrial computers, which are evaluating data of the actuator/sensor level. For a connection to the higher systems, transfer of bigger data sets with critical times of response are necessary.

• The actuator/sensor level is part of the field level and is connecting the technical process with the controller. This is done by simple field devices like sensors and actuators. Here, a quick and cyclic updating of input and output data is in the centre of interest, whereas short messages are being transferred. The time for updating of input- and output data has to be marginally shorter than the cycle time of the controller.

Introduction


Interbus-S – one of the first

Already in 1985 the Interbus-S was developped by Phoenix Contact, in order to

integrate extensive parallel wiring into PLC periphery. In the beginning it was not the

task of Interbus-S to perform a universal communication medium, it was only

connecting programmable logic controllers, CNC controllers or process automation

systems to their peripheral devices. Today INTERBUS-S offers a wide range of

different communication levels with one protocoll. The benefits of Interbus-S are its

high transmitting efficiency at very few data of each participant. Therefore, the

Interbus-S is only suitable for the lowest hierarchy level. It is combining sensors and

actuators with controllers, it is not providing a networking of controllers among

eachother.

Profibus – the allrounder

The Profibus (Process Field Bus) is suitable as multi-master protocol for networking

of devices, which are providing more complexity. The Profibus is EN standardized.Its

area of use is broad and applies from field level up to master level. The Profibus in

its principles is providing operation also down to the sensor-/actuator level.

However, for an economical connection of a higher number of sensors and

actuators, it is more profitable to apply a faster bus on a lower level (for ex. AS-I).

AS-I – fast and small

This bus system is specialized on demands of the lowest level (Actuator-Sensor-

Interface). AS-I is combining binary and analog actuators and sensors with the first

control level and is substituting cable harness, control cabinets and terminal strips.

Meanwhile, many producers are offering intelligent sensors and actuators

connectable to AS-I, in order to transmit more information than 1 and 0.

AS-I is providing easy handling - by cut-and-clamp technique, field devices are

simply clamped on to the unprotected 2-wire flat cable. Thus, installation may be

done even by persons without specific know-how.

CAN – fieldbus on wheels

The CAN-Bus System (Controller Area Network) had been originally concepted by

Bosch in co-operation with Intel in order to reduce cable harness inside the auto-

mobile. If the demands on automotive bus systems and industrial fieldbus systems

are to compare, one would find amazing similarities: less costs, functionality under

difficult environmental conditions, high real-time ability and ease of handling. The

bus system is suitable to networking of intelligent sensors and actuators within a

machine.

Short description of important Fieldbus-systems

Introduction


The term "AS-I" derives from actuator-sensor-interface. One could translate:

interface between actuators, sensors and the PLC. This bus system is a networking

system for the lowest field level of the automation area - the process level. On the

process level, data throughput is very less, because interchange of signals of the

connected devices (switches, buttons, BERO, contactor relays, solenoid valves etc.)

is only binary. However, demands on the rate of data transfer are very high.

Mechanical as well as electrical specifications for the ASI-bus have been prepared by

11 competent companies working in the field of actorics, sensorics and construction

of controllers. In this case, a manufacturer-independent standard of sensors and

actuators could be developped. Besides this, an AS-I association was founded to

evaluate all AS-I components for their compatibility to the standard and then awards

the AS-I-logo.

The ”Verein zur Förderung busfähiger Interfaces für binäre Aktuatoren und Sensoren

e. V.“ (association for the development of bus compatible interfaces for binary

actuators and sensors) made it their business to support use and spreading of the

AS-I system and to proceed specification, standardization, certification and general

information of the users. The development of a small IC made it possible to integrate

the AS-I bus also directly into small devices. Caused by this, innovative new

generations of actuators and sensors could come up.

Further new benefits were arising, as there are:

• Elimination of cable harness between sensors, actuators and PLC • Quick and simple assembly • Automatic bonding by cut-and-clamp technique • High protection against interferences • High protection IP67, therefore possibility of local operation • Self-healing bus cable

Actuator Sensor Interface – AS-I

Introduction


The technical data and transmission protocol of the AS-Interface are fixed in the standard EN 50 295.

Concerning the AS-Interface, the following data of performance are given:

• max. 31 AS-i-participants with 4 bit I/O effective data • max. 124 I/O sensors and actuators • access procedure by cyclic polling at master-slave-procedure • cycle time max. 5ms • error security, identification and repetition of interferred telegrams • the medium of transmission is a simple two-core wire (2 x 1,5 mm²) for data and

2 A auxiliary energy maximum for each AS-I string. Supply voltage is 30 V DC. The signal of the data transfer is modulated. Additional supply of auxiliary energy 24 V DC is possible

• connection and mounting of AS-I components in throughput technology • AS-i-slave-module with an integrated circuit (AS-i-chip), which are not in need of

a processor and as well of no software. Therefor results nearly non-delayed telegram processing and a small volume of the slaves.

• special AS-I sensors and –actuators with directly integrated AS-i-chips as well. • flexible construction opportunities like electric installation techniques • length of wiring max. 100m or 300m (with repeater)

The AS-Interface is a single-master system. Therefore, in a system, there is always existing one master and up to 31 slaves. If there are further slaves necessary, another AS-Interface system with another master has to be installed.

Actuator Sensor Interface – AS-I

Introduction


Creation of the AS-Interface is modular by using the following components:

• power supply 30 V DC directly connected to the data cable • AS-I data cable is an unprotected yellow two-core wire. Connection of the AS-I

components is done in throughput technique, whereas the AS-I wire is providing a profile in order to avoid wiring errors by installation.

• AS-i master as coupling unit for control of the user or of an higher ranking bus system with the resp. master chips. The AS-I master is providing access for the user to the I/O data of the AS-I slaves. On the S7-300 this is done in the user program of the CPU.

• AS-i slaves with slave ASIC: There is existing a big collection of slaves of different manufacturers for the AS-Interface. By commissioning, every slave has to be allocated a definite AS-I address, which is then stored in it. Addressing is done either by a projecting device or by the master, whereas every slave is single connected and inscribed by the addressing telegram. This is also working, if a slave is substituted.

If an AS-I slave is consuming more than 100 mA or total consumption of AS-I slaves together is over 2 A of auxiliary energy for each AS-I string, then an additional power supply is to provide. Also AS-I output slaves are supplied by external voltage, in control technology normally 24 V DC. This is being connected over the AS-I power cable (black) to the auxiliary energy contacts of the slaves. For the auxiliary energy, the AS-I mains is connected as unshielded black two-core wire. Connection to auxiliary energy is done by throughput technique. The AS-I wire is profiled to avoid wiring errors by installation.

AS-I –basic components

AS-I – additional energy

Introduction


If the AS-I Master is switched on, it is interrogating all possible addresses (1-31)

during its setup. If a slave replies, its address and its profile is saved in a table. The

profile of a slave is a combination of numbers, which determines its kind. For

example, the 4 input-board has 0.0, an inductive sensor 1.1.

After interrogation of all addresses, the AS-I Master has installed a complete list of

all participants. Also it is possible to stipulate a project list; the AS-I Master is

comparing its actual list with the stipulated one and is reporting differences to the

PLC, as for example "wrong address" or "participant not available".

This communication is occuring cyclically and is lasting 5 ms in a full expanded

system. All existing addresses are interrogated at each AS-I-cycle, which contains

slave reports, parameter reports as well as a diagnosis report.

The AS-I Master is sending a message to one bus participant after the other (transfer

of output data). The requested addresses are provided from its list, which was

installed during his setup. If there is no reply on its interrogation, it is immediately

repeated by the AS-I Master. If then there is also no reply, he starts working on the

other addresses. During the next two cycles, the AS-I Master is trying to interrogate

the missing address again, if the reply is still not coming, a configuration error bit is

set, which may be interrogated and processed by the PLC.

Furthermore, a parameter interrogation of an address is possible each cycle and

enables adjustment of switching area of a sensor.

Additionally a diagnosis interrogation is done at each cycle, which means, the AS-I

Master is demanding an address, which is not on its list. Caused by this, it is

possible to recognize a new participant after 30 cycles maximum (150 ms) and to

respond it over the PLC and the AS-I Master.

Furthermore, sensors, actuators and slaves may be changed during operation

without roughly disturbing of the sequence or crash of a running program.

AS-I – run of communication

Introduction


Data transfer is taking place over unshielded and oil-resistant two-core AS-I data line, which is connected to a power supply of 30 V DC. The signal is being modulated on this voltage level.

0 SB A3 A2 A1 A0 I4 I3 I2 I1 I0 1PB I3 I2 I1 I0 PB

IBSTIBST

master call master-break

slave-break

slave answer

In this case, the following bits are relevant for data transfer:

�ST = starter bit �SB = control bit �Q4 ... Q0 = address of the slave (5 bit ) �I4 ..... I0 = information from master to the slave (5 bit ) �I3 ..... I0 information from slave to the master (4 bit ) �PB = parity bit �EB = end bit

Because only the master can start a call, the telegram is very short including less protocol overhead. Caused by this and also by a limited number of slaves, the input-/output data may be updated very quickly and the AS-Interface must not be operated by a high data stream. This is also the reason, why the AS-Interface is less sensible for interferences caused by electro-magnetic fields.

Besides a cheap price, this robustness is one of the decisive advantages compared with other systems, which have to carry much more of protocol overhead, like for example the PROFIBUS with ist variety of communication opportunities.

AS-I – data transfer and transmission security

Introduction


A master call with answer of the slave is executed by the AS-Interface like follows:

Master call

• The starter bit ST is marking the start of a master call (ST = 0). • The control bit SB qualifies the data- (SB = 0), address- (SB = 0), parameter- (SB

= 0) and command call (SB = 1). • The address of the called slave is content of the 5 bits A4 ... A0. • The part of information from the master to the slave is transmitted in the 5 bits I4

... I0. • The parity bit PB ensures, that the total sum of the „1‘s“ of the master call is

even. Now the slave is able to recognize, if the transmission of the call has been executed without errors.

• The end bit is marking the end of a master call (EB = 1). • The master break between 3 .. 10 bit times is intercalated for ensuring of

transmission security.

Slave answer

• The starter bit ST is marking the start of the slave answer (ST = 0). • The part of information from slave to master is transferred in the 4 bits I3 ... I0. • The parity bit PB ensures, that the total sum of all „1‘s“ of the slave answer is

even. Now the master is able to recognize, if the transmission of the answer was executed without errors.

• The end bit is marking the end of the slave answer (EB = 1). • The slave break between 3 .. 10 bit times is intercalated for ensuring of

transmission security.

By means of this procedure of transmission, a very high transmission security is ensured. Single, double and triple errors are recognized in any case. Errors of 4-5 times are recognized by a probability of 99,9999%. Because all slaves are being called by the master at every cycle, the failure of a component is recognized immediately.

Maintenance errors, like for example wrong addressing are recognized and indicated by a permanent comparison of the nominal and actual configuration in the master.

Introduction


If one is comparing the costs of an installation for controlling a machine by AS-I Bus or by conventional parallel wiring, the results are amazing:

• costs for AS-I installation are 5 % less • assembly costs are 75 % less • material costs are ca. 20 % more

Furthermore, mounting time may be decisively reduced, because mounting of electrical and mechanical components can be done together. Further costs are to be saved by reduction of production depth and variety of parts by using standardized and pre-fabricated elements (stock-keeping). Above all, by using of the AS-I cable probability of wiring error is reduced.

If all these costs are added and calculated, it comes out, that an application of AS-I is reaching the "break-even-point" at ca. 4 actuators.

Further benefits, arising of the specific features of the AS-I Bus system:

• Complete pre-assembly of construction elements • Simple test procedure • Increase of flexibility (expandability) • Reduction of total complexity • Reduction of planning and projecting expediture • Opportunity to upgrade planning forecast Reduction of the entire manufacturing process

AS-I – economical installation

Introduction


The following graphics shows an example of a PLC-configuration with AS-I-Master a CP 342-2 and a CPU 313C-2 DP, as well as a standard 24 VDC power supply and a 30VDC AS-I power supply.

AS-I – connection example with slaves 4 bit, 8 bit

Introduction


The connection of inputs and outputs to the different kind of slaves is as follows:

AS-I-M12-plug – View upon screw-/clamp side

Allocation listing (input signal) of a 3-wire sensor: 1 = + = brown 2 = signal = black 3 = - = blue

Allocation listing (input signal) of a vacuum switch: 1 = + = brown 2 = signal = black 3 = - = blue

Allocation listing (input signal) of a 2-wire-reed switch, Festo SMEO-4U-K-LED-230: 1 = + = black 2 = signal = brown

Allocation listing (input signal) of a 3-wire- reed switch, Festo SME-8-K-LED-24: 1 = + = brown 2 = signal = black 3 = - = blue

Allocation listing (input signal) of a micro switch: 1 = + = brown 2 = signal = green

Allocation listing (output signal) of lights/motors: 3 = - = brown/red 4 = signal = blue/black

AS-I – input/output connection to the slave M12 (4 bit) and clamp (8 bit)

Introduction


AS-I-Slave 8 bit with clamps (example connection to IN1 and OUT1 each)

Allocation listing (input signal) of a 3-wire sensor: 5 = + = brown 6 = signal = black 7 = - = blue

Allocation listing (input signal) of a vacuum switch: 5 = + = brown 6 = signal = black 7 = - = blue

Allocation listing (input signal) of a 2-wire-reed switch, Festo SMEO-4U-K-LED-230: 5 = + = black 6 = signal = brown

Allocation listing (input signal) of a 3-wire- reed switch, Festo SME-8-K-LED-24: 5 = + = brown 6 = signal = black 7 = - = blue

Allocation listing (input signal) of a micro switch: 5 = + = brown 6 = signal = green

Allocation listing (output signal) of lights/motors: 8 = - = brown/red 9 = signal = blue/black

Introduction


To see the connection of the pneumatic valve terminal please refer to the following graphicss:

1 connection of the two inputs In1 and In2 as well as 24 VDC power supply 2 connection of external power supply for the output 3 AS-I-data line 4 connection of the output (valve Y 20.1)

AS-I – input/output connection to the pneumatic valve interface

Introduction


The functions of the LED´s of the pneumatic valve interface are:

LED display

ASI-LED (green) Fault-LED (red) Description

On Off Asi-Interface voltage applied, no fault

Off Off No Asi-Interface voltage on bus

Flashing On Asi-Interface address not set (equals zero)

On Flashing Short circuit / overload at inputs

Off Flashing Short circuit / overload at outputs

flashing On Failure of bus communication (Watchdog expired)

AUX PWR-LED (green) Description

On Load voltage applied

Off Load voltage applied

Status-LED (green/yellow) Description

on 1- Signal at In/Output

off 0- Signal at In/Output

The function of the dip-switches on the pneumatic valve interface are:

Setting DIP switch setting *

With load voltage **

(factory setting)

1,2: off

3,4: on

With load voltage ***

(seal the “24V DC” connection with

blanking plug type ASI-SD-FK-BL))

1,2: on

3,4: off

* Black = pressed

** The outputs/valves are provided with power via the additional supply (standard FMS50 setting)

*** The outputs/valves are provided with power via the AS-I-Interface bus

Introduction


Each slave has to be identified within the AS-I-network by an address between 1-31 for each master (CP 342-2) before connecting the slave into the AS-I-network. To define the slave adress, there are different possibilities and devices. The following graphics shows the possibility to define the address using the Programming and Service Device (PSG) from Siemens.

1. switch on PSG (START) 2. confirm indication (ENTER) 3. choose Master (F3) 4. choose individual operation (F1) 5. choose new address (F1) 6. confirm AS-I-address (ENTER) 7. input new address (2) 8. confirm entry (ENTER) 9. back to main menue (2x ESC) 10. switch off (F4)

AS-I – slave addressing with programming and service device

Introduction


The following graphics shows the possibility to define the address using the AS-I addressing device.

The handling of this addressing device is so easy and clear, that there is no need of explanation to do it. Just the connection, especially of the 4I/4O-module is interesting.

AS-I – slave addressing with addressing device

Introduction


The following graphics shows the possibility to define the address using the AS-I addressing device.

The handling of this addressing device is so easy and clear, that there is no need of explanation to do it. Just the connection, especially of the 4I/4O-module is interesting.

Introduction


Addressing of the AS-I slaves inputs and outputs is depending on the installation of the PLC hardware and on the setup of the PLC-modules. The following example is referring to the standard configuration of hardware installation at Festo FMS50 conveyor with AS-I.

The address range of the AS-I slaves, resulting from this installation of the PLC hardware is:

• Input byte addresses from 256….271 • Output byte addresses from 256…271

This address range depends on the cord location of the AS-I master and can be checked within the hardware configuration, which is part of the chapter Programming

AS-I – absolute hardwareaddresses within the S7 PLC program

Introduction


The AS-I slaves are not directly addressable within the program, because AS-I slaves are treated as periphery. This is the reason, why the following program part inside of the organization block is absolutely necessary, in order to address the slaves. Within the following example we use the addresses, which are standardized used with a Siemens S5 PLC – byte 64 – 79 in total per one master. This is facilitating the change from the S5 world - in which this address range is fix determined - to the world of the S7, where this address range is actually free choosable:

L PID256 load peripheral-input-double word 256 T ID64 transfer to input-double word 64 L PID260 load peripheral-input-double word 260 T ID68 transfer to input-double word 68 L QD64 load output-double word 64 T PQD256 transfer to peripheral-output-double word 256 L ID68 load output-double word 68 T PID260 transfer to peripheral-output-double word 260

In order to facilitate the programming in the Organization Block, double words are being transformed – every program line needs time (relatively!).

The input-/output double words are consisting of 4 bytes:

ID 64 = IB 64, IB 65, IB 66, IB 67 ID 68 = IB 68, IB 69, IB 70, IB 71 QD 64 = QB 64, QB 65, QB 66, QB 67 QD 68 = QB 68, QB 69, QB 70, QB 71

Single bytes also may be loaded and transferred, for example:

L PIB 256 T IB 64 L PIB 257 T IB 65 a.s.o.

T QB 64 L PQB 256 T QB 65 L PQB 257 a.s.o.

Introduction


The peripheral address of the inputs and output-bits are concerning the slave address which the sensors and/or actuators are connected to. Please refer to the following list of a the maximum in- and outputs used within one master.

7 6 5 4 3 2 1 0

PLC-Address Bit Bit

PIB/PQB 256 Flags slave address 1

PIB/PQB 257 slave address 2 slave address 3















Regarding our definition to use the same addresses than with a S5 PLC (refer to one page before), and transformation from peripheral to usable addresses, the list looks like:

7 6 5 4 3 2 1 0

PLC-Address Bit Bit

IB/QB 64 Flags slave address 1

IB/QB 65 slave address 2 slave address 3















AS-I – peripheral addresses regarding the slave address

Introduction


Example 1: A microswitch is connected to a slave number 3 at IN4: • search for slave address 3 (2nd column/2nd line) • IN4 means, the 4th possible bit of together 4 bit (bit 0 -bit 3) = bit 3

consequently the absolute address = I 65.1 Example 2: A DC-motor is connected to a slave number 4 at OUT2: • search for slave address 4 (1st column/3rd line) • OUT2 means, the 2nd possible bit of together 4 bit (bit 4 -bit 7) = bit 5

consequently the absolute address = Q66.5 Example 3: A 3-wire sensor is connected to a slave number 4 at IN2: • search for slave address 4 (1st column/3rd line) • IN2 means, the 2nd possible bit of together 4 bit (bit 4 -bit 7) = bit 5

consequently the absolute address = I66.5 Example 4: A light is connected to a slave number 5 at OUT3: • search for slave address 5(2nd column/3rd line) • OUT3 means, the 3rd possible bit of together 4 bit (bit 0 -bit 3) = bit 2

consequently the absolute address = Q66.2

Introduction


Frequency converters are transforming the alternate current net with a fixed voltage supply and frequency into a new threee-phases net. Voltage supply and frequency are changeable within the new net. By changing the frequency the rotation speed will be changed and therefore the speed of the actuator.

The frequency converter controls the acceleration and deceleration of the closed loop conveyor as you can see within the following graphicss:

t0…t1 acceleration t1…t2 maximum speed t2…t3 deceleration

Frequency converter – general informations

Introduction


The frequency converter Micromaster 420 is available with different control panels. The Basic Operator Panel – BOP is the standard which enables the user to adjust all neccessary parameters.

Introduction


Main features

• easy to install, parametise and commission • short and reproduceable activation time on controlling signals • extensive offer of parameters to configure for a wide range of applications • easy cabling • modular structure for flexible configurations • high control frequency for noiseless motor movement • external options for PC-data transmission, basic control panel a.s.o. • advanced operator panel (AOP) and Profibus-data transmission module

Functional features

• Field Current Control (FCC) for a better dynamics and better motor control • Fast Current Limitation (FCL) for non-switch-off operation mechanics • integrated direct current break system • system brake for better braking power • acceleration and deceleration time with programmable smoothness • closed loop control with Proportional/Integral function (PI)

Safety features

• complete safety for motor and converter • saftey agains too high/too low voltage power • temperature saftety system for the converter • ground connection safety system • short circuit safety system • I2 t-motor temperature safety system

Introduction


Description of the Control Panel functions

Button Function Description

Display of conditions

the LCD is showing the actual settings of the converter

Converter Start

start of the converter. The pre-condition of the Start-button is inactive. To activate, please change the parameter P0700 = 1

Converter Stop

Stop 1: by pressing the button once, the converter stops with the actual deceleration speed. The pre-condition of the Stop-button is inactive. To activate, please change the parameter P0700 = 1.

Stop 2: by pressing the button twice oder pressing and holding longer than 3 seconds, the motor decelerates freely

Changing direction

by pressing this button, the direction of the motor will be changed. The opposite direction will be shown by a minus or a blinking decimal point. The pre-condition is inactive. To activate, please change the parameter P0700 = 1

Motor jog mode

by pressing and holding this button and if the converter has no output voltage signal, the motor is running with the pre-selected Jog-frequence. After the button will be released, the motor will stop. Pressing this button if the motor is running, has no influence

Functions This button can be used to display additional informations. This button has to be pushed and hold and the display is showing the following informations, based on any defined parameter:

1. voltage of the direct current circuit (d)

2. output current (A)

3. output freuquence (Hz)

4. output voltage (o)

5. the value pre-selected in P0005

Functions see the example changing of the speed

Increase/decrease value

by pressing this buttons, the displayed value can be increased or decreased. To change the frequency debit value via the BOP please change the parameter P1000 = 1

Introduction


Company settings

The following table shows the company settings of the parameters. Any parameter has an allocated value which can be changed by the user.

Introduction


Example reduce of the speed (from company setting 50 to 35)

Button Description Display

press to access to the parameters r0000

press as long as P1082 appears P1082

press to reach the level to parametise P1082 50.00

press as long as reaching the maximum frequence 35.00

press to save the parameter and exit P1082

press as long as r0000 appears r0000

press to exit 35.00

the LCD is changing between the debit and the actual frequence 00.00

Introduction


Parameters of the motor

The first step of commissioning is to adapt the parameters of the used motor into the converter. Please refer to the data sheet or data plate of the motor to see the parameters:

• Parameter P0304 motor nominal voltage • Parameter P0305 motor nominal current • Parameter P0307 motor nominal power • Parameter P0308 motor nominal power factor • Parameter P0309 motor nominal efficiency • Parameter P0310 motor nominal frequency • Parameter P0311 motor nominal speed

Introduction


Additional user defined parameters

A sudden acceleration or deceleration of the motor can be avoided by using ramp parameters. This achieves a reduced start and stop movement of the motor. This is neccessary for an exact positioning of the motor and is used mostly to reduce the start-up current of the motor.

• Parameter P1120 (function refer to the graphicss)

• Parameter P1121 (function refer to the graphicss)

Introduction


• Parameter P1130 (function refer to the graphicss) • Parameter P1131 (function refer to the graphicss) • Parameter P1132 (function refer to the graphicss) • Parameter P1133 (function refer to the graphicss)

tup total = ½ P1130 + X*P1120 + ½ P1131 tdown total = ½ P1132 + X*P1121 + ½ P1133 X = x * fmax

Another parameter is for the movemement speed. It can be adjusted by changing the parameters P1080 and P1082 changing the frequency.

Both parameters are related to a fixed frequency band and can be changed only within this band.

• Parameter P1002 fixed frequency minimal • Parameter P1003 fixed frequency maximum • Parameter P1080 minumim frequency • Parameter P1082 maximum frequency

Introduction


Adjustments for the conveyor

Parameter description Param.number User adjustm. Company adjustm.

User access level P0003 3 1

Parameter filter P0004 3 21

Parameter group for commissioning

P0010 0 = no adjustment

possible

1 = changing of parameters

possible

Motor nominal voltage [V] P0304 230 ***

Motor nominal current [A] P0305 0,68 ***

Motor nominal power [W] P0307 0,11 ***

Motor nominal speed [1/min]

P0311 3100

Fixed frequency [Hz] P1001 50 0

Minimum frequency [Hz] P1080 50 0

Maximum frequency [Hz] P1082 60 50

Ramp-up time [s] P1120 3 10

Ramp-down time [s] P1121 3 10

The parameters P1001 until P1005 (fixed frequency) representing a frequency frame, where the parameters P1080 and P1082 can be changed within.

Introduction


Example to adjust the conveyor speed

1. switch on the power supply main switch 2. press P on the converter control panel 3. choose parameter P0010 with the ∧/∨ button on the control panel 4. press P 5. choose the value 1 with the ∧/∨ buttons 6. press P 7. choose parameter P1080 with the ∧/∨ buttons 8. press P 9. choose the value 50 Hz with the ∧/∨ buttons 10. press P 11. choose the parameter P0010 with the ∧/∨ buttons 12. press P 13. choose the value of 0 with the ∧/∨ buttons 14. press P 15. switch off the power supply main switch and on again


Please list up all the “sensors” and “actuators” shown in the picture below (1 – 3). Name the elements with identification in the wiring diagram/pneumatic plan and describe shortly their function generally (not the function within the system).

Information

Please use the technical manual-data sheets, pneumatic plan and wiring diagrams. Please refer to the examples (Ex.1 – Ex.3) mentioned below in the table of the execution work-sheet. Please follow the numbers (1 – 3) shown in the pictures below (Ex.1 is not shown in the graphicss).

NOTICE:

Planning

Please plan your project within the whole team carefully. Use the technical manual and the real station to do this project. Please describe the function of the element in general, not within the signal- and materialflow of the station. To find the data-sheet of the elements, please see the list of components first and check the order no. printed on the element itself. The time to finish this project should be around 1,5 hours.

1.1 Analysis – Components identification

Commissioning

Commissioning


Execution/Documentation

Please complete the list regarding the elements shown and numbered in the pictures above.

No. Name Ident. Description Page #

Ex.1 Start-button S1 Push button with light on the control panel,

normally open contact, connected to a PLC-

input

no data sheet

Panel: inputs

Ex.2 Proximity

switch,

inductive

Bx0.1 Inductive switch, normally open contact,

activated by metal workpiece, nominal

switch distance 2,5 mm, maximum

switching frequenz 900 Hz

SIEN-M8NB-PS-S-L

Station: inputs

PLC-board: inputs

Ex.3 Proximity

switch,

inductive

Bx0.5 Inductive switch, normally open contact,

activated by a magnet ring in the piston rod

of the short storke cylinder 2, send the

information “piston rod of the cylinder is in

front position” to the PLC-input

SME-8-S-LED-24

Station: inputs

PLC-board: inputs

No. Name Ident. Description Page #

Commissioning


Please analyze the connections of the Emergency Stop system within your station and complete the drawing on the next page (Execution and Documentation).

Information

Please fill out all in the graphics and draw the connections. Use the real station to check the connections.

NOTICE:

Planning

Please follow the explanations of the instructor first and then plan your activities step-by-step. Use the real station to find out all connections and identifications. Use also the technical documentation. Please refer to the following graphicss to see the Emergency Stop system. The time to finish this project should be around 2,0 hours.

1.2 Analysis – Emergency Stop system

Commissioning


Commissioning



Commissioning


Please complete the below mentioned list of input- and output adresses of the PLC regarding the definition, to use the Siemens S5-addresses from 64-…79. Please define your own symbol adress using max. 8 characters.

Information

To find out the adresses, please refer to the technical manual-wiring diagram of the station and the Control Panel and the theoretical part of AS-I within this documentation. The pneumatic components can be activated by the manual detection button on the valve. The standard configuration of the station numbers and the connected MPS-stations are defined as follow (please refer to the drawing on the next page): (the configuration of the connected MPS-stations can be redefined, but the station numbers are fixed. To redefine the stations, please refer to 1.7 Commissioning – Download Project and Test). Please use the following table to define the hardware addresses:

7 6 5 4 3 2 1 0

PLC-Address Bit Bit

















1.3 Analysis – Input and Output adresses

Commissioning


Standard configuration of the FMS50:

1. Conveyor station number 1 2. Conveyor station number 2 3. Conveyor station number 3 4. Conveyor station number 4 5. Conveyor station number 5 6. Conveyor station number 6 1.1 MPS-station 1 - Distribution and Testing station 2.1 MPS-station 2 - Processing and Handling station 3.1 MPS-station 3 - Vision system 4.1 MPS-station 4 - Robotassemby station 5.1 MPS-station 5 - Automatic Storage and Retrieval System (ASRS) 6.1 MPS-station 6 - Sorting and Handling station (1.1…6.1 are mentioned from outside to the conveyor) For further informations regarding the numbers of the MPS-stations and the conveyor-stations, please refer to 1.7.1 Commissioning – Driver Control

Commissioning


NOTICE:

Planning

Please plan your activities within your team. Check the inputs in the wiring diagram and at the slaves directly. The time to finish this project should be around 1,0 hour.


Please complete the list of the inputs and outputs of your station.

I/O Station 1

Slave Module Funct. Ident. Addr. Symbol Description

02 ASI-4E-B, 4 Inputs M12 IN1 Station 1- pallet at stopper

IN2 B10.2 I65.5 01_Cong Station 1- congestion sensor inductive

IN3 B10.3 I65.6 01_Wpav Station 1- workp.on pallet sensor optical

IN4 B10.4 I65.7 01_Wpcou Station 1- workp. counter

03 EVA-MF-2E1A-Z, 2 Inputs, 1 Output, IN1 B10.5 I65.0 01_Strel Station 1- stopper is released

pneumatic valve interface IN2 X X X Not used

OUT1 Y10.1 Q65.2 01Stopre Station 1- release stopper

04 3RG9002-0DB00, 4 Inputs, IN1 Station 1- Comm.input 1

4 Outputs, terminal screw IN2 I66.5 01_Co_I2 Station 1- Comm.input 2

IN3 I66.6 01_Co_I3 Station 1- Comm.input 3


OUT1 Q66.4 01_Co_Q1 Station 1- Comm.output 1


OUT3 Q66.6 01_Co_Q3 Station 1-Comm. output 3


Commissioning


I/O Station 2


05 ASI-4E-B, 4 Inputs M12 IN1 B20.1 I66.0 02_Palav Station 2- pallet at stopper

IN2 Station 2- congestion sensor inductive






07 3RG9002-0DB00, 4 Inputs, IN1 I67.0 02_Co_I1 Station 2- Comm.input 1

4 Outputs, terminal screw IN2 Station 2- Comm.input 2







I/O Station 3




IN3 Station 3- workp.on pallet sensor optical







IN3 Station 3- Comm.input 3






Commissioning


I/O Station 4





IN4 Station 4- workp. counter












I/O Station 5













OUT1 Station 5- Comm.output 1




Commissioning


I/O Station 6

















I/O Control Panel


direct Control panel inside the control SH4 I0.0 AUTOON Automatic on button

cabinet SH5 i0.1 AUTOOF Automatic off button

LSH4 Q0.0 L_AUTOON Light inside Automatic on button

LSH5 Q0.1 L_AUTOOF Light inside Automatic off button

Q0.7 Conveyor Motor conveyor

Commissioning


Please complete the below mentioned list of input- and output adresses of the PLC regarding the definition, to use the Siemens S5-addresses from 64-…79. Please define your own symbol adress using max. 8 characters.

Information

To find out the adresses, please refer to the technical manual-wiring diagram for the station and the Control Panel and the theoretical part of AS-I within this documentation. The pneumatic components can be activated by the manual detection button on the valve. The standard configuration of the station numbers and the connected MPS-stations are defined as follows (please refer to the drawing on the next page): (the configuration of the connected MPS-stations can be redefined, but the station numbers are fixed. To redefine the stations, please refer to 1.7 Commissioning – Download Project and Test). Please use the following table to define the hardware addresses:

7 6 5 4 3 2 1 0

PLC-Address Bit Bit

















1.4 Analysis – Input and Output adresses expanded

Commissioning


Standard configuration of the FMS50:

1. Conveyor station number 1 2. Conveyor station number 2 3. Conveyor station number 3 4. Conveyor station number 4 5. Conveyor station number 5 6. Conveyor station number 6 1.1 MPS-station 1 - Distribution and Testing station 2.1 MPS-station 2 - Processing and Handling station 3.1 MPS-station 3 - Vision system 4.1 MPS-station 4 - Robotassemby station 5.1 MPS-station 5 - Automatic Storage and Retrieval System (ASRS) 6.1 MPS-station 6 - Sorting and Handling station (1.1…6.1 are mentioned from outside to the conveyor) For further informations regarding the numbers of the MPS-stations and the conveyor-stations, please refer to 1.7.1 Commissioning – Driver Control

Commissioning


NOTICE:

Planning

Please plan your activities within your team. Check the inputs in the wiring diagram and at the slaves directly. The time to finish this project should be around 1,5 hour.


Please complete the list of the inputs and outputs of your station.

I/O Station 1






03 EVA-MF-2E1A-Z, 2 Inputs, 1 Output, IN1 Station 1- stopper is released











Commissioning


I/O Station 2








OUT1 Station 2- release stopper


4 Outputs, terminal screw IN2 Station 2- Comm.input 2







I/O Station 3




IN3 Station 3- workp.on pallet sensor optical













Commissioning


I/O Station 4

















I/O Station 5

















Commissioning


I/O Station 6

















I/O Control Panel


direct Control panel inside the control SH4 I0.0 AUTOON Automatic on button

cabinet Automatic off button

LSH4 Q0.0 L_AUTOON Light inside Automatic on button

LSH5 Q0.1 L_AUTOOF Light inside Automatic off button

Motor conveyor

Commissioning


Please check the adjustment of all sensors, mechanical and pneumatical components and the Emergency Stop wiring of your station to prepare the test of the whole process.

Information

To find out the function and location of the sensors, please use the technical manual. The inputs can also be checked directly at the AS-I-slave. To move pneumatic actuators, please switch off the air-pressure and move them manually by hand. Please refer to the following graphicss to see the position of the workpiece on the pallet.

1 direction of movement

NOTICE:

1.5 Commissioning – Adjustment of the Station

Commissioning


Planning

Please plan your activities within your team. Check the inputs in the wiring diagram and at the AS-I-slaves. Check the adjustment of the mechanical components first. Check the connection of the Emergency Stop system. The time to finish this project should be around 3,0 hour.


Write down the single steps and all useful informations. Write down your single steps you did to proceed.

Step No.: Description Check

1 check the adjustment of mechanical components

2 check the adjustment of mechanical actuators holder

3 check the mechanical position of hand over to the next station

4 cable connections (Emergency, I/O-communication…)

5 connect all power supplies

6 check the adjustment of sensor holders

7 check the adjustment of sensors in the holders

8 check the adjustment of sensitivity of sensor

9 tubing connections

10 connect all air-pressure supplies (careful! turn pressure down)

11 check the adjustment of the speed of pneumatic actuators

12 connect the stations together

13 communication connection

Commissioning


Please check the adjustment of all sensors, mechanical and pneumatical components and the Emergency Stop and I/O-communication wiring of your station to prepare the test of the whole process.

Information

To find out the function and location of the sensors, please use the technical manual. The inputs can also be checked directly at the AS-I-slave. To move pneumatic actuators, please switch off the air-pressure and move them manually by hand. Please refer to the following graphicss to see the position of the workpiece on the pallet and see the I/O-communication from the conveyor to the MPS-stations on the next pages.

1 direction of movement

1.6 Commissioning – Adjustment of the Station expanded

Commissioning


I/O-communication Distribution station – Testing station – Conveyor station 1

OU

T 0.

7

IN 0

.1

PART AV

IN 0

.1

PART AV

IN 0

.7

IN 0

.7

PART ONPALLET

TRANSPORTAS-i

IN ........

IN 2 IN 3OUT 2OUT 3

IN 1OUT 0OUT 1

SYSLINK (AS-i)

Distribution Station Testing Station

AS-I Addr: AS-I Addr:AS-I Addr:AS-I Addr:

AS-I Addr:AS-I Addr:


4mm Lab cable

Signal

0 V

SYSLINK

IN 2

IN 3

OUT 3

0 V

Transport System

IN 4IN 5OUT 4OUT 50V

OUT 6OUT 7

IN 6IN 7

0V


OUT 6OUT 7

IN 6IN 7

0V


OUT 6OUT 7

IN 6IN 7

0V

Station 1 ready

0V

Stations ready

Palette free0V 0V

Commissioning


I/O-communication Processing station – PICalfa station – Conveyor station 2

Processing Station PIC alfa Station Transport System

OU

T 0.

7

OU

T 0.

7

IN 0

.1

PART AV

IN 0

.1

PART AV

IN 0

.7

IN 0

.7

PART ONPALLET

TRANSPORTAS-i

IN ........

IN 2 IN 3OUT 2OUT 3

IN 1OUT 0OUT 1

SYSLINK (AS-i)




Convert sensor to IN/OUTPUT-Positiondissemble el. Push-out

Part ready for

Rotation release

No application for FMS50


OUT 6OUT 7

IN 6IN 7

0V


OUT 6OUT 7

IN 6IN 7

0V

Processing ready for part

0V

4mm Lab cable

Signal

0 V

Stations ready

Pending order

Run release

0V 0V

SYSLINK

IN 2

IN 3

OUT 3

0 V

Commissioning


I/O-communication Vision system – Conveyor station 3

PART ONPALLET

TRANSPORTAS-i

IN ........

SYSLINK (AS-i)SYSLINK

I/O-Terminal

SIMATIC VS710




OUT2OUT3 Part NIO

Quality evaluated IN 2IN 3

IN 0IN 1Part IO/NIO (1/0)

Station ready OUT0OUT1

IN 2IN 4

OUT 2OUT 3

OUT 0OUT 1

Pending orderIN 0IN 1

0V 0V24V 24V

Vision Transport System

I/O-cabel twisted with SYS-Link-plug(black marking Order Nr. 167 106)

Commissioning


I/O-communication Robot assembly – Conveyor station 4

IN 0

IN 2IN 3IN 4

IN 6IN 7

PART ONPALLET

TRANSPORTAS-i

IN ........

Transport System

01: Assembly10: Sorting out11: at bus: load part on palette

IN 8

IN 10IN 11IN 12

IN 14IN 15

OUT 0

OUT 2OUT 3OUT 4

OUT 6OUT 7OUT 8

OUT 10OUT 11OUT 12

OUT 14OUT 15

I/O-Terminal Magazine

I/O-Terminal Robot

Operation panel

Robot assembly station

In FMS50 Mode the sensor signals and are

not transfered to the robot. The released input is used for coding ofthe stations´orders (In6, In7)

PART AV FOLLOWING STATION FREEPART AV

Foll.stat.FREE

START

X1 X2 X3

X4

STOPRESET

B2(Orient.)

B1(colour)

IN 2 IN 3

OUT 2OUT 3

IN 0IN 1

OUT 0OUT 1

SYSLINK (AS-i)

AS-I Addr: AS-I Addr:




Station readyOrder aktiv (busy)

ERR CODE #0ERR CODE #1

PART AVFOLl. stat. Free

0V0V

I/O-cabel twisted with SYS-Link-plug(Red marking Order Nr. 121 210 )

Commissioning


I/O-communication ASRS – Conveyor station 5

PART ONPALLET

TRANSPORTAS-i

IN ........

SYSLINK (AS-i)

Station AS/RS Transport System

IN 2 IN 3

OUT 2OUT 3

IN 1

OUT 0OUT 1

AS-I Addr: AS-I Addr:




Control panel new

SYSLINK - plug

Cabel

Order aktiv (busy)

Stock is fullStock is empty

Station ready

OUT 6

OUT 7

IN 6

IN 7

IN 4

OUT 4

OUT 5

0V 0V

SYSLINK

IN 2

IN 1

IN 0

IN 3

OUT 3

OUT 1

OUT 0

OUT 2

0 V

Pending order Bit0 Order

0 X No processing

1 1 Retrieval, jungest part

1 1 Storage1 0 Retrieval, oldest part

Bit1

X

1

01

1 0 Reserved0

Pending order

Order Bit1Order Bit0

Commissioning


I/O-communication Sorting station PICalfa station – Conveyor station 6

PIC alfa stationTransport System

Stations readyFOL Stat. FREE*

4mm Labor cable

Sorting station ready

0V

Expiry as in the case of MPS standard:

if a palette with workpiece is in Ap6 and the PIC alfa set signal free, the transport control sets share AV* thesignal . This signal must be evaluated in the program of the station PIC alfa instead of the signal share AV . PIC alfa station get the part and the signal share AV* disappears again, the pallet can drive on . AV* is a combination from the sensor share ON PALLET and the condition pallet IN position.

Transport SystemAS-i

SYSLINK (AS-i)

AS-I Addr:

IN 2 IN 3

OUT 2OUT 3

IN 0IN 1

OUT 0

0V


OUT 6OUT 7

IN 6IN 7

0V

OUT

0.7

IN 0

.1

IN 0

.7PART AV

OUT

0.7

IN 0

.1

IN 0

.7

PART AV


OUT 6OUT 7

IN 6IN 7

0V0V

Sorting Station not ready, if:- it was not started (START-Button activated)- slides are full with workpieces- no voltage supplied to the station- the station does not exist

Signal

0 V

SYSLINK

IN 2

IN 3

OUT 3

0 V

Sorting/Commissioning station

NOTICE:

Commissioning


Planning

Please plan your activities within your team. Check the inputs in the wiring diagram and at the AS-I-slaves. Check the adjustment of the mechanical components first. Check the connection of the Emergency Stop system and I/O-communication to the MPS-stations. The time to finish this project should be around 4,0 hour.


Write down the single steps and all useful informations. Write down your single steps you did to proceed.

Step No.: Description Check

1 check the adjustment of mechanical components

2 check the adjustment of mechanical actuators holder

3 check the mechanical position of hand over to the next station

4 cable connections (Emergency, I/O-communication…)

5 connect all power supplies

6 check the adjustment of sensor holders

7 check the adjustment of sensors in the holders

8 check the adjustment of sensitivity of sensor

9 tubing connections

10 connect all air-pressure supplies (careful! turn pressure down)

11 check the adjustment of the speed of pneumatic actuators

12 connect the stations together

13 communication connection

Commissioning


Please download the full project into the PLC and test the full process without any connected MPS-stations.

Information

Please make sure that the PC is connected to the PLC with the communication cable, the power supply (main switch) of the station is on, air-pressure of around 5 bar is available , all emergency switches are deactivated and the CPU-switch is in STOP position. Make sure that the PLC memory is empty (delete) and the power supply of all connected MPS-stations is off and change the Emergency Stop connection to the MPS-stations with the connectors which are used if there is no MPS-station available (with the short cut between plug 3 and 4).

The control elements of the control cabinet of the transport system are required for the start-up of the transport system and, as such, the complete system.

Main switch conveyor

The main switch is located on the side of the control cabinet of the transport system station, supplying the control cabinet with voltage. The conveyor belts and the system can only be started, if the control cabinet receives voltage supply.

1.7 Commissioning – Download Project and Test

Commissioning


Control elements of the Transport system

Name Element Function

Error H8 Flashes Indicator Acknowledge error

Automatic on is flashing

Flashes Indicator Start-up request H5

Light on Indicator system in operation Automatic on

S5 Start up system

H6 Light on Indicator Automatic off Automatic off

S6 Switch off motors of the conveyor belts

H1 Light on Indicator Controller off

Controller off S1

Transport system is being completely de-activated

(cp. EMERGENCY-STOP).

H3 Light on Indicator Request

Acknowledge EMERGENCY-STOP Controller on

S3 Acknowledge EMERGENCY-STOP

EMERGENCY-

STOP S2 De-activate control / EMERGENCY-STOP function

The table assists in operating the conveyor transport system station. All of the push-buttons and lamps are described within. After downloading of the PLC-program, please switch the CPU to RUN first. Activate the controller by pressing the button Controller on once and after the light Automatic on is flashing, please press this button to run the conveyor. Please be aware, that if all connceted MPS-stations are off, the pallets don´t stop at the connected MPS-stations. After that, please connect the Emergency Stop connection to the MPS-stations and switch on the power supply of all MPS-stations and start the homing procedure. After that, the pallets must stop for a short time at each station where a MPS-station is connected.

Commissioning


NOTICE:

Planning

Please follow the description of the in instructor carefully step-by-step. Use the NOTICE field to write down the single steps to proceed. The time to finish this project should be around 2,0 hours.

Commissioning



File Open Browse (select subdirectory – example here D:\Eigene Dateien\Eigene Daten\Teach_gb\Festo\MPS_Conveyor FMS50) FMS50 OK (left mouse button)

Commissioning


(click with the left mouse button onto the project Conveyor) PLC Download (follow the instructions on the screen to download the project – after download is finish, switch the CPU-switch to RUN and test the program)

Commissioning


The Driver Control is very important to define which MPS-station is connected to which conveyor station. The entire conveyor program is done by using variables for each station. This allows us to be very flexible by changing MPS-stations to each conveyor station. If the Driver Control is not correct, let´s say the MPS-station number 1 (Distribution/Testing) is not activated within the Driver Control, the entire program will ignore the MPS-station. So this data, which is part of the DB1 (Data Block 1), are very important to be checked and to be correct. Please follow the screen shots and explanations in the following to get an idea about how to check and how to change this variables.

Please be reminded, that the numbers in front of the stations and programs within the first screen shot on this page can be different within your solution. Its only important to open the Simatic 300-Station which is named as xxxxConveyorXXX.

+xxxConveyorxxx +CPU313C-2DP +S7 xxxConveyorxxx BlocksBausteine

1.7.1 Commissioning – Driver Control

Commissioning


DB1 (double click) View Data View

Commissioning


(Move to the top end of the list and refer to the numbers mentioned at IX1…IX8). This list is for an example FMS50 configuration as follows:

Adress Name Type Initial value Actual value Comment

108 IX1 Byte B#16#0 B#16#1 MPS-stat.1 connected to conv.stat.1

109 IX2 Byte B#16#0 B#16#0 no MPS-stat.connected







Commissioning


This above mentioned list is just an example of a possible FMS50 configurationlike:

1 MPS-station 1 - Distribution/Testing is connected to conveyor station 1 4 MPS-station 4 - Robot/Robotassembly is connected to conveyor station 4 5 MPS-station 5 - ASRS is connected to conveyor station 5 6 MPS-station 6 - Sorting/Handling is connected to conveyor station 6

Basically, the MPS-stations have the following numbers:

1 Distribution/Testing 2 Processing/Handling 3 Vision system 4 Robot/Robotassembly 5 ASRS 6 Sorting/Handling

and can be connected to each conveyor station you want. So please understand, that the MPS-station number 1…6 has nothing to do with the conveyor station number IX1…IX8

Commissioning


Another example of a system and the list of the DB1:

Adress Name Type Initial value Actual value Comment









Commissioning


(If you changed the variables, which you should not do within the entire conveyor program, please save the DB1) File Save

Commissioning


(and download the new DB1 into the PLC) PLC Download (follow the messages on the screen)

Commissioning


(and close the window) File Exit

Commissioning


After downloading of the entire project (1.7 Commissioning – Download Project and Test) or changing of the DB1 (1.7.1 Commissioning – Driver Control) you are able to check the Driver Control variables online. Please make sure, that you are still connected to the PLC and the CPU is switched to STOP. Please proceed as follows:

PLC Monitor/Modify Variables

1.7.2 Commissioning – Online check of the Driver Control

Commissioning


Table Open

Commissioning


(make sure that the BlocksBausteine of the Conveyor station is open – left window)

TreiberDriver Control OK

Commissioning


(here you can see which MPS-station is connected to which conveyor station. After viewing, please exit the window) Table Exit


Please define the PLC-hardware used within your station with the STEP 7 software. After the configuration, please download it into the PLC.

Information

Please make sure that the PC is connected to the PLC with the communication cable, the power supply of the station is on, the emergency switch is deactivated and the CPU-switch is in STOP position. Make sure that the PLC memory is empty (delete). Use the screen shots (execution) to proceed. Open a new project and name it P2_01_Co. It´s not necessary to add the station name into the hardware configuration name, because the configuration is the same for all stations.

NOTICE:

Planning

Please follow the description (screen shots) carefully step by step. Please make sure, that every member of your team did the hardware configuration at least once. The time to finish this project should be around 1,0 hours.

2.1 Programming – Hardware-configuration

Programming

Programming


Execution

Screen shots of the hardware configuration, the bold words are commands to click on, the ( ) are only comments (ENTER) means click left mouse button once or press ENTER, (double click) means double click the left mouse button:

File New (type Name: P2_01_Co) OK

Programming


Insert Station SIMATIC 300 Station

Programming


+ P2_01_Co SIMATIC 300(1) Hardware (double click)

Programming


+ SIMATIC 300 + RACK-300 Rail (double click)

Programming


(Click on Slot 2) - RACK 300 + CPU-300 + CPU 313C-2DP 6ES7 313-6CE00-0AB0 (depends on the CPU you use – check the order no. on the front left below corner of the CPU) (double click) (we don’t use any networking like MPI or Profibus-DP at the moment, that’s why – not networked is ok) OK

Programming


CPU 313C-2DP (at the Slot 2 – double click) Cycle/Clock Memory Clock Memory 100 (Memory Byte – free definition)

Programming


Retentive Memory 0 (Number of Memory Bytes Starting with MB0) 0 (Number of S7 Timers Starting with T0) 0 Number of S7 Counters Starting with C0) OK

Programming


(Click on Slot 4) - CPU-300 + CP-300 + AS-Interface CP 342-2 AS-I (6GK7 342-2AH01-0XA0 depends module you use – refer to the left below corner of the module to find the right number) (double click)

Programming


- SIMATIC 300 Station Save and Compile

Programming


(Distinguished to the S5 PLC-family of Siemens, you could change the AS-I peripheral addresses if you want – for example we want to change the input and output peripheral byte 256…271 to the standardized addresses 64…79 used within the S5 PLC´s, you please proceed like shown into the screen shot) CP 342-2 (Slot 4 double click) Addresses (change the address of the Inputs Start to 64 and the Outputs Start also to 64 and deactivate the System selection of in- and outputs)

OK

PLEASE DON´T PROCEED TO CHANGE THE ADDRESSES TO 64…79

Programming


PLC Download (follow the instructions on the screen to download the hardware configuration)

Programming


(After download without an error message switch the CPU to RUN - no red light SF/BF - switch the CPU to STOP again) Station Exit

Programming


Controll

If there will be no error message after saving and compiling your hardware configuration and no error message while or after downloading, the hardware configuration have been done properly.

Change the switch on the CPU to RUN-position-if there is no read light SF/BF the configuration was successful and then change the switch to STOP again.

Documentation

Please add your own comments to the screen shots.

Programming


Please edit the OB1 within the project P2_01 to transfer the peripheral AS-I-addresses into addressable addresses used by Simatic S5 (64…79).

Information

The AS-I slaves are not directly addressable within the program, because AS-I slaves are treated as periphery. This is the reason, why the following program part inside of the organization block is absolutely necessary, in order to address the slaves. Within the following example we use the addresses, which are standardized used with a Siemens S5 PLC – byte 64 – 79 in total per one master. This is facilitating the change from the S5 world - in which this address range is fix determined - to the world of the S7, where this address range is actually free choosable:

L PID256 load peripheral-input-double word 256 T ID64 transfer to input-double word 64 L PID260 load peripheral-input-double word 260 T ID68 transfer to input-double word 68 … L PID268 load peripheral-input-double word 268 T ID76 transfer to input-double word 76 L QD64 load output double word 64 T PQD256 transfer to peripheral output-double word 256 L QD68 load output double word 68 T PQD260 transfer to peripheral output-double word 260 … L QD76 load output double word 76 T PQD268 transfer to peripheral output-double word 268 Please make sure that the PC is connected to the PLC with the communication cable, the power supply of the station is on, the Emergency Stop switch is deactivated and the CPU-switch is in STOP position. Make sure that the PLC memory is empty (delete). Use the screen shots (Execution) to proceed.

NOTICE:

Planning

Please follow the description (screen shots) carefully step by step. Please make sure, that every member of your team did the hardware configuration at least once. The time to finish this project should be around 1, 0 hours.

2.1.1 Programming – Transfer of the peripheral AS-I-adresses within OB1

Programming


Execution

(After closing the Hardware configuration window) +SIMATIC 300(1) +CPU 313C-2DP +S7 Program(1) Blocks (double click on OB1)

Programming


OK

Programming


(Edit the program like shown within the screen shot)

Programming


File Save File Exit

Programming


Please edit the PLC-program concerning the following description: as long as an Automatic on-button AND an Automatic off-button are pressed, the piston rod of the cylinder move. The cylinder is actuated by a 5/2-way single solenoid valve. Please use the pneumatic cylinder of the conveyor station 3 for this and all following exercises.

Information

Use FC5 to edit the program. Save the project P2_01_Co as the new project P2_02_Co (see screen shots). We didn’t close the project P2_01_Co, because we have to save this project with a new name. Please use symbol addresses for this and all following projects (see the screen shots on the following pages how to edit the symbol table). The programming language of FC5 should be FBD (Function Block Diagram), in OB1 STL (Statement List). FC5 starts unconditional (UC).

NOTICE:

2.2 Programming – Basics in Digital Technology – AND

Programming


Programming


In the following please find some important information regarding pneumatic actuators and their triggering. These informations are basically.

NOTICE:

• 5 = number of connections (1, 3, 4, 2 and 5) • 2 = 2 switching positions (2 rectangles) The connections have the following functions:

1(P) = air connection (supply) 2(B) = output B for backward stroke 3(S) = connection exhaust air of forward stroke 4(A) = output A for forward stroke 5(S) = connection exhaust air of backward stroke

In the following drawing you can find letters in brackets behind the standardized designation of the connections (1, 3, 4, 2 and 5). These letters are former designations, one can still find them on old elements.

3(R)5(S)1(P)

14

y1

4(A) 2(B)

y2 y33(R)5(S)1(P)

14 124(A) 2(B)

Single solenoid Double solenoid

Activation of single/double solenoid valve:

Programming


3(R)5(S)1(P)

14

y1

power(24VDC)

connected to Y1

4(A) 2(B)

3(R)5(S)1(P)

14

y1

4(A) 2(B)

Activation of a single solenoid valve:

shortpowersignal

(24VDC)connected to y2

y2 y2y3 y33(R) 3(R)5(S) 5(S)1(P) 1(P)

14 1412 124(A) 4(A)2(B) 2(B)

shortpowersignal

(24VDC)connected to y3

Activation of a double solenoid valve:

Programming


Planning

Please plan your project step by step first within the group. Work out the informations of truth table, wiring diagram, logic plan and stepping diagram first together with the Instructor. Before programming, don’t forget to delete the contents of the PLC using the CPU-switch. Follow the screen shots to save the project P2_01 with a new name, edit the symbol table and OB1 and insert and edit FC5. The time to finish this project should be around 3,0 hour including theory.

There are two possibilities to structure a project where four Programs are parallel to the Station SIMATIC 300(1) this structure is used for education, because there is mostly more than only one different exercise (Programs) for one station.

Struc02 shows a typical industrial structure, because there is mostly only one Program for one station or application. All the following projects have to be done in this structure.

Programming


Execution

“Copy” the project P2_01 into the new project P2_02 with the command Save as….

(Click on P2_01_Co) File Save as (type the new name P2_02_Co) OK

Programming


Programming


Edit the symbol table with the symbol editor

+P2_02_Co +SIMATIC 300(1) +CPU 313C-2DP S7 Program(1) Symbols

(double click) (edit all symbols and hardware addresses for all stations)

Programming


(After editing all stations) File Save File Exit

Programming


Insert a Function FC5 into the project P2_02 and expand the OB1 with the unconditional call of the FC5

+S7 Program(1) Blocks Insert Function

Programming


(Type in the name of the FC) FC5 (choose the correct programming language) FBD

OK

Programming


(Double click onto OB1) (click on Network 2) Insert Network

Programming


(Edit Network 3 like shown in the screen shot) File Save File Exit

Programming


Editing the FC5 with the AND-function

(After editing) File Save (no error message) File Exit

This procedure is always the same after editing a program it´s not mentioned anymore!!!

Programming


Block PLC Download (it´s not necessary to download the System data again, so please choose no if this question appears and follow the instructions on the screen)

This procedure to download a project is always the same after editing a program it´s not mentioned anymore!!!

Controll

After editing and downloading the project into the CPU, please test the function according the project description. Please use the Online function also like shown on the next screen

Programming


(Re-open FC5 by double click on it) Debug Monitor (you can see the function of the logic online on the monitor. Please switch the monitor mode off again before exit the program) Debug Monitor File Exit

Programming


Please edit the PLC-program concerning the following description: as long as an Automatic on button OR an Automatic off button is activated, the piston rod of the cylinder moves. The cylinder is actuated by a 5/2-way single solenoid valve.

Information

Use FC1 to edit the program. Save project P2_02 as the new project P2_03. Please use the symbol addresses shown in the list of inputs and outputs of Project 1.3 to edit the program. The programming language for FC1 should be FBD, for OB1 STL. The FC1 shall start unconditional. The following screen shows the project structure and the symbol editor.

NOTICE:

2.3 Programming – Basics in Digital Technology – OR

Programming


Programming


Planning

Please plan your project step by step first within the group. Use the list of inputs and outputs of the Project 1.3. Work out the informations of truth table, wiring diagram, logic plan and stepping diagram first together with the Instructor. Before programming, don’t forget to delete the contents of the PLC using the CPU-switch again. After editing OB1 and FC1, please download the Blocks into the CPU and test the program. The time to finish this project should be around 1,0 hour including theory.


Program OB1:

Programming


Program FC1:

If you click the right mouse button on an input or output and click on Insert Symbol., you will get a list of all defined inputs and outputs within the Symbol Editor.

Controll

Edit the project and download it. Test the function according the project description.

Programming


Please edit the PLC-program concerning the following description: if an Automatic on button is pressed shortly, the piston rod of the cylinder with single solenoid shall move as long as an Automatic off button is pressed shortly. If the Automatic on- and the Automatic off button are pressed at the same time, the piston rod shall not move out.

Information

Use FC1 to edit the program. Save the old project P2_03_Co as the new project P2_04_Co. Please use symbol addresses. The programming language of FC1 should be FBD, for OB1 STL.

NOTICE:

2.4 Programming – Basics in Digital Technology – RS-Flip-Flop

Programming


Programming


Planning

Please plan your project step by step first within the group. Use the list of inputs and outputs of the Project 1.3. Work out the informations of truth table, wiring diagram, logic plan and stepping diagram first together with the Instructors. Before programming, don’t forget to delete the contents of the PLC using the CPU-switch. The time to finish this project should be around 1,5 hour including theory.


Program OB1 is the same than for project before. Program FC1

Programming


Controll

Edit the project and download it. See the function of the project online on your computer. Test the function according the project description.

Programming


Please edit the PLC-program concerning the following description: as long as an Automatic on button is pressed AND an Automatic off button is NOT activated, the piston rod of the cylinder with single solenoid shall move.

Information

Use FC10 to edit the program. Please use symbol addresses. The programming language for FC10 should be FBD, for OB1 STL. The FC10 shall start unconditional. Work out the Truth Table together with the instructor first.

Instructor: Please work out the Truth table together with the participants. Show how to negate an input in the program with FBD. Explain that within the program they shall use the cylinder with single solenoid valve not the light H1.

Planning

Please plan your project step by step first within the group. The time to finish this project should be around 0,5 hour.

2.5 Programming – Basics in Digital Technology – AND NOT

Programming



Program OB1

Programming


Program FC10

Controll


Watch FC10 with the online-function (description see Project 2.4).

Programming


Please edit the PLC-program concerning the following Truth table. Reduce the logic as much as possible. Use the Automatic on button (S) and the Automatic off button (R) and the cylinder with single solenoid valve (H1).

Information

Use FC1 to edit the program. Name the project P2_06_Co. Please use symbol addresses. The programming language for FC1 and for OB1 should be STL. The FC1 shall start unconditional.

NOTICE:

Planning

Please plan your project step by step first within the group. The time to finish this project should be around 0,5 hour.

2.6 Programming – Basics in Digital Technology – IDENTITY

Programming



Program OB1

Programming


Program FC1

Controll


Watch FC1 with the online-function.

Programming


After a short actuation of an Automatic on button, the piston rod of the cylinder with single solenoid shall move as long as an Automatic off button is pressed shortly. The cylinder shall not move, if both buttons are pressed at the same time. The program shall only be active, if a pallet is at the stopper, the program FC8 is not running if no pallet is in place.

Information

Use FC8 to edit the program. The project name is P2_07_Co. Please use symbol addresses. The programming language for FC8 is FBD, for OB1 STL.

NOTICE:

Planning

Please plan your project step by step first within the team. Discuss the differences to call a function (FC) with and without a condition. The command for conditional call is CC. Before the action of CC, you have to edit a condition-which condition is this? The time to finish this project should be around 1,0 hour.

2.7 Programming – Condition Call of a Program

Programming



Program OB1

Programming


Program FC8

Controll


Watch the function of the FC with the online-function. This control step will be the same for all the following projects, so it´s not mentioned in each project anymore.

Programming


Expand the Project 2.7 (P2_07_Co) after a short actuation of an Automatic on button, the piston rod of the cylinder with solenoid valve shall move as long as an Automatic off button is pressed shortly. The cylinder shall not move, if both buttons are pressed at the same time. The program shall only be active, if a pallet is at the stopper, the program FC8 is not running if no pallet is in place with the additional function the piston rod move to the starting position if no pallet is in place during running of the program in.

Information

Use FC8 to edit the program. Please use symbol addresses. The programming language for FC8 should be FBD, for OB1 STL.

NOTICE:

Planning

Please plan your project step by step first within the team. Before programming, don’t forget to delete the contents of the PLC from the computer. Edit the project (programs) on a sheet of paper first. The time to finish this project should be around 1,0 hour.

2.8 Programming – Condition Call of a Program expanded

Programming



Program OB1

Program FC8 is the same than for the project before.

Programming


If an Automatic on button is pressed and hold, the light inside the Automatic on button shall be on after 5,0 seconds and stay on as long as the button is pressed. The timer is only running while the Automatic button is pressed. If the button will be released before 5 seconds, the timer starts new.

Information

Use FC1 to edit the program. The programming language for FC1 should be FBD, for OB1 STL. Use the Hardware catalog (Overviews) to edit the program in FBD and use the help-function to get further informations (see the screen shots "Help function for an On-Delay-Timer"). Use Timer 1 for this project.

NOTICE:

Planning

Please plan your project step by step first within the team. Check out the function of all timers with the help function and choose the right timer for your project. May be it´s helpful, to print the help-functions of the timers for further projects. Edit on a sheet of paper first. The time to finish this project should be around 2,0 hour including theory and print out of the different timers.

2.9 Programming – On-Delay-Timer function

Programming



Program OB1

Programming


Help functions in Step 7

+ Timers S_ODT (F1 opens the help function and you can see a description of the timer)

Programming


Program FC1

Programming


If an Automatic off button is pressed, the light inside the Automatic off button shall be on as long as the button is pressed. If you release Automatic off, the light will be on for another 3 seconds.

Information

Use FC1 to edit the programs. Please use symbol addresses. The programming language for FC1 should be FBD, for OB1 STL. Use Timer 2 for this project.

Planning

Please plan your project step by step first within the team. Check out the function of all timers and choose the right timer for your project. Edit on a sheet of paper first. The time to finish this project should be around 1,0 hour.

2.10 Programming – Off-Delay-Timer function

Programming



Program FC1, the program OB1 is the same than for the project before

Programming


If an Automatic on button is pressed, the piston rod of the cylinder move until reaching the sensor for the front/back position depending on the hardware and then move back to starting condition automatically. After starting 5 times, the light inside the Automatic on button must be on and the piston rod can not move again. Set the counter by pressing the Automatic off button once.

Information

Use FC1 to edit the programs. Please use symbol addresses. The programming language for FC1 should be FBD, for OB1 STL. Use Counter 1 for this project.

NOTICE:

Planning

Please plan your project step by step first within the team. Check out the function of all counters as shown for the timers in the Project 2.9 and choose the right counter for your project. Edit on a sheet of paper first. The time to finish this project should be around 2,0 hour including theory and print out of the different counters.

2.11 Programming – Counter Down function

Programming




The logic module P (M10.0) is an edge memory this means, even you hold Start-button down, only a short pulse will come through to the input. Some contact shatter or bounce even you press them only once.

Programming


As long as an Automatic on button is pressed, the light inside the Automatic on button flashes with 500 ms on and 500 ms off. The program of FC1 should be done with only one Network.

Information

Use FC1 to edit the programs. Please use symbol addresses. The programming language for FC1 should be FBD, for OB1 STL. There is a Memory byte (Clock Memory) defined within the Hardware configuration which automatically flashes with different frequencies or different time periods. Please see the following time periods for the 8 Bits of the Memory byte 100 (100 is free defined within the Hardware configuration). A time period is the time the Memory is on and the time the Memory is off:

M100.0 = 0,1 sec. M100.1 = 0,2 sec. M100.2 = 0,4 sec. M100.3 = 0,5 sec. M100.4 = 0,8 sec. M100.5 = 1,0 sec. M100.6 = 1,6 sec. M100.7 = 2,0 sec

NOTICE:

Planning

Please plan your project step by step first within the team. Check out the Hardware configuration in Project 2.1 again how to define and activate the Clock Memory . The time to finish this project should be around 0,5 hour.

2.12 Programming – Programming of a Flashlight

Programming




Programming


The starting condition for this project is to press the Automatic on button shortly. After the Automatic on button was pressed shortly, the light inside the Automatic on button is on for 1 second. After the Automatic on light is off, the light inside the Automatic off is on for 3 seconds cycle end. Restart of the cycle can be done in two different ways: no pallet is at the stopper (I72.0 is off), the cycle has to be restarted by pressing the Automatic on button again (Manu-cycle) or a pallet is at the stopper (I72.0 is on) restarts the cycle automatically (Auto-cycle).

Information

Even there is a pallet at the stopper, the very first cycle has to be started by pressing the Automatic on button, the following cycles starts automatically (if a pallet is still at the stopper, or by pressing the Automatic on button again, if the pallet is no more available at the stopper position.) Use FC1 to edit the program. Please use symbol addresses. The programming language for FC1 should be FBD, for OB1 STL. The first start of the cycle must be by pressing Start-button, not with Auto/Manu-switch.

NOTICE:

Planning

Please plan your project step by step first within the team. The time to finish this project should be around 2,0 hour.

2.13 Programming –Programming of a Auto/Manu sequence

Programming




Programming


A pallet should be detected at station 6 of the conveyor. The Automatic on button starts the process (start conveyor) and the Automatic on light is on. The process is active until the CPU switch is in RUN position. CPU switch to Stop position ends the cycle. If a pallet will reach the station, the pallet stops for 2 seconds and will be released after the time is finish.

Information

For this exercise, we have to change the starting position of all stopper cylinders excluding station 6, which means, the position have to be changed from front to back position. Please use only one pallet on the conveyor. FC1 in FBD, OB1 in STL.

NOTICE:

Planning

Please plan your project step by step first within the team. Discuss the possibilities to change the piston rod position of the stopper cylinders of station 1-5 first. Define the programming sequence first step by step on a paper first. The time to finish this project should be around 2,0 hour.

2.14 Programming – Conveyor movement

Programming




Programming


A workpiece on a pallet should be detected at station 6 of the conveyor and indicated by the light inside the Automatic off button. The Automatic on button starts the process (start conveyor and check of the workpieces) and the Automatic on light is on. The process is active until the CPU switch is in RUN position. CPU switch to Stop position ends the cycle. If a pallet reaches the station, the pallet stops and the light barrier checks if there is a workpiece in place. If yes, the Automatic on light is on and the pallet can be released by pressing the Automatic off button once and the process restarts again automatically. If there is no workpiece available, the pallet will be released.

Information

For this exercise, we have to change the starting position of all stopper cylinders excluding station 6, which means, the position have to be changed from front to back position. The position of the workpiece on the pallet is shown in the following graphics. Please use only one pallet on the conveyor. FC1 in FBD, OB1 in STL.

NOTICE:

Planning

Please plan your project step by step first within the team. Discuss the possibilities to change the piston rod position of the stopper cylinders of station 1-5 first. Define the programming sequence first step by step on a paper first. The time to finish this project should be around 3,0 hour.

2.15 Programming – Conveyor movement expanded

Programming




Programming


Programming


Please complete the following graphics according the description.

Information

Work out the basics of input/output communication together with the instructor first.

Planning

Please plan your project step by step first within the team. The time to finish this project should be around 1,0 hour.


Please define a 1 Bit bidirectional communication network:

24 VDC 0 V Input Output

PNP24 VDCInput: 0-12 VDC=0-Sig.12-30 VDC=1-Sig.Output:1-Sig.=24 VDC

PLC



PLC

2.16 Project – Basics of I/O– communication

Programming


Please define a 1 Bit unidirectional communication network from PLC to Robot-Controller:



PLC


PNP12 VDCInput:0- 6 VDC=0-Sig.6-12 VDC=1-Sig.max.volt.30 VDCOutput:1-Sig.=12 VDC

Robot-Controller

Programming





PLC


PNP12 VDCInput:0- 6 VDC=0-Sig.6-12 VDC=1-Sig.max.volt.30 VDCOutput:1-Sig.=12 VDC

Robot-Controller

Programming





PLC


NPN12 VDCInput:0- 6 VDC=1-Sig.6-12 VDC=0-Sig.Output:1-Sig.=0 VDC

Robot-Controller

Programming


Please test the input/output-communication between the conveyor and one of your connected MPS-stations by a PLC-program. Complete the drawing shown in the Execution step first.

Information

Please use only one program FC1 in FBD which starts without any condition to solve this problem. The OB1 is in STL. Fill out all in the drawing. The binary communication like input/output communication is very important basic knowledge to understand the next level of communication – Fieldbus Technology!

NOTICE:

Planning

Please plan your project step by step first within your team and communicate with the team of the connected station also to complete your drawing. Finish the drawing first and then work out which button, lights or actuators you will use for this project and write it into the drawing. The time to finish this project should be around 1,5 hour.

2.17 Project – Test the I/O– communication

Programming



This drawing is an example for the communication between the Testing station and the conveyor.

Programming


Program FC1, OB1 is the same than in the project before

Controll

Edit the project and download it. Test the function according the project description and your planning. Watch FC1 with the online-function.

Programming


This project combines two PLC´s via Profibus-DP, if corresponding PLC´s are available. The communication shall be based on a 1-bit bidirectional communication which means that as long as a button is pressed on the Master PLC station control panel, a light at the slave PLC control panel is and opposite.

Information

Please define the inputs (button) and outputs (lights) by yourself. Please edit the program FC1 in FBD which starts without any condition. The OB1 is in STL. Please follow the screen shots shown within the Execution step. The following solution is based on the configuration shown in the graphics:

NOTICE:

2.18 Project – Communication via Profibus-DP

Programming


Planning

Please work out the theory of Fieldbus technology together with the Instructor first. Please connect both Profibus-DP interfaces and the PC´s with the PLC´s like shown in the graphics above. Normally the programming of a Profibus network is done by only one PC, but because we are working out the projects by teams, the Master and the Slave solution should be done by both teams. The Master team is downloading the Master solution into the Master PLC and the Slave team is downloading the Slave solution into the Slave PLC. Please plan by yourself who is corresponding for which PLC. Please follow the screen shots very carefully and discuss your solution steps within the whole team. . The time to finish this project should be around 3,0 hour.

Programming



The following description is based on the definition of 1 Byte with the address field of input/output byte 40. This means, that there is a Profibus-DP address field of I40.0 – I40.7 and Q40.0 – Q40.7. As you can see, from the program-controlled point of view Profibus-DP is nothing else but an I/O-communication.

Insert a Subnet and two Simatic-300 Stations

File New (type in the name P2_18_Co) OK Insert Subnet 2 PROFIBUS

Programming


Insert Station 2 SIMATIC S7-300 (change the name to Slave)

Programming


(Click on the project P2_18_Co) Insert Station 2 SIMATIC S7-300 (change the name to Master)

Programming


Hardware configuration of the DP-Slave

(Click on Slave) Hardware (double click) +SIMATIC 300 +RACK-300 Rail (double click)

Programming


(Click on Slot 2) -RACK-300 +CPU-300 +CPU 313C-2DP 6ES7 313-6CE00-0AB0 (double click) PROFIBUS(1) 4 (Profibus-DP address) OK

Programming


CPU 313C-2DP (Slot 2 double click) Cycle/Clock Memory (click on Clock memory) 100 (Memory Byte)

Programming


Retentive Memory (type in 0 like shown within the screen shot) OK

Programming


DP (Slot X2 double click) DP-Slave (type in the name)

Programming


Operating Mode (click on DP-Slave)

Programming


Configuration New (Address type choose Input) 40 (Address) Apply

Programming


New (Address type choose Output) 40 Apply Close

Programming


Station Save and Compile (follow the screen) Station Exit

The Slave team must download the hardware configuration into the Slave PLC before exit.

Programming


Insert OB82 and FC1 into the Slave

+Slave +CPU 313C-2DP +S7 Program(1) Blocks Insert S7-Block Organisation Block OB82 (type in the Name) (choose STL) OK

There is no need to program the OB82, but the Profibus-DP communication use this OB to transfer data to start-up the communication.

Programming


Insert S7-Block Function FC1 (type in the name) (choose FBD) OK

Programming


Edit FC1 of the Slave

(Edit the program like shown within the screen shot) File Save File Exit

Programming


Hardware configuration of the Master

(Click on the Master station) Hardware (double click) +SIMATIC 300 +RACK-300 Rail (double click)

Programming


(Click on Slot 2) -RACK-300 +CPU-300 +CPU 313C-2DP 6ES7 313-6CE00-0AB0 (double click) PROFIBUS(1) 2 (type in the address) OK

Programming


CPU 313C-2DP (Slot 2 double click) Cycle/Clock Memory (click on Clock memory) 100 (type in the Memory Byte)

Programming


Retentive Memory (type in 0 like shown within the screen shot) OK

Programming


DP (Slot X2 double click) DP-Master (type in the name)

Programming


Operating Mode (check if the DP-Master is active) OK

Programming


(Click on the line PROFIBUS(1) DP master system(1)) - SIMATIC 300 +PROFIBUS DP +Configured Stations CPU 31x (double click) Connect OK

Programming


(Double click on the symbol of the Slave CPU) Configuration (click onto line 1)

Edit

Programming


(Choose address type Output) 40 (type in the address) Apply

Programming


(Click on line 2) Edit (choose address type Input) 40 (type in the address) Apply Close Station Save and Compile Station Exit

The Master team must download the hardware configuration into the Master PLC before exit.

Programming


Copy Symbols and OB1 from the project before and insert OB82

File Open (choose the project P2_17_Co) OK +P2_17_Co +SIMATIC 300(1) +CPU 313C-2DP S7 Program(1) +P2_18_Co +Master

+CPU 313C-2DP Symbols (right mouse button in the project P2_17_Co) Copy

Programming


S7 Program(2) (in the project P2_18_Co) (right mouse button) Paste

Programming


+S7 Program(1) (in the project P2_17_Co) Blocks (right mouse button click onto OB1) Copy

Programming


+S7 Program(2) (in the project P2_18_Co) (right mouse button) Paste OK

Programming


Insert S7-Block Organisation Block OB82 (type in the name) (choose STL) OK

Programming


Insert S7-Blocks Function FC1 (type in the name) (choose FBD) OK

Programming


Edit of FC1, the OB1 is the same than in the project before

(Edit the program like shown within the screen shot) File Save File Exit

After editing, the Slave team shall download the full Slave project into the Slave PLC and the Master team into the Master PLC. Test the project.


In the following exercises there are some programming errors which have to be detected, located and eliminated.

Information

The programs have been part of the programming projects.

NOTICE:

Planning

Please follow the steps: error detection (what is not working) , error location (where can the error be logically), error elimination (find out the error location, change the program and test the sequence).

Controll

Test the program according the short description given by the instructor on the board.

3.1 Program – Trouble Shooting

Trouble Shooting

Trouble Shooting


Error description:

Trouble Shooting


Original Project

Trouble Shooting


Error description:

Trouble Shooting


Original Project

Trouble Shooting


Error description:

Trouble Shooting


Original Project

Trouble Shooting


Error description:

Trouble Shooting


Original Project

Trouble Shooting


Error description:

Trouble Shooting


Original Project

Trouble Shooting


Error description:

Trouble Shooting


Original Project

Trouble Shooting


Error description:

Trouble Shooting


Original Project

Trouble Shooting


Error description:

Trouble Shooting


Original Project

Trouble Shooting


Error description:

Trouble Shooting


Original Project

Trouble Shooting


Error description:

Trouble Shooting


Original Project

Trouble Shooting


Error description:

Trouble Shooting


Original Project

Trouble Shooting


Error description:

Trouble Shooting


Original Project

Trouble Shooting


The following error within a program was not part of the programming projects.

The Project-description is:

If the Auto/Manu-switch is off a program FC1 shall be active, if the Auto/Manu-switch is on, a program FC2 shall be active. FC1 is a NOR-function with the Start-light (H1), the FC2 is a NAND-function with the Reset-light (H2). Use the Start- and Reset-button as inputs.

Error description:

Trouble Shooting


Original Project

Trouble Shooting


Trouble Shooting


Trouble Shooting


Please test the full process including all conditions. Find out which part of the process is not working properly and proceed with the steps: error detection, error limitation and error elimination. Please don’t forget to fill out the working-sheet of the part Execution and Documentation. The original project shall be Project 2.18.

Information

Besides Commissioning and Programming, the Trouble Shooting and Maintenance is one of the most important tasks in reality, because non-operating manufacturing units are causing high costs.

It is much more important than in installation&commissioning or programming, to train operational steps to detect, limitate and eliminate an error as quick as possible.

At Trouble Shooting there is one difference between so called “Commissioning Errors“ and “Maintenance Errors”. Both of them could be different in a way, there are NO wrong wirings, tubing’s as well as programming errors within the Maintenance Errors, because the system already has been running perfectly and an operational error had happened. Such operational errors could be:

• break of wire • defect of elements like valves, cylinders, motors, sensors, etc. ... • break of program • mechanical reasons Procedure of error elimination divides into three important fields:

• error detection • error limitation • error elimination which have to be documented respectively by the trainee on the attached work sheet. An example helps with the further procedure.

Usually maintenance errors are easier to transform into manual training, therefore this Teachware is referring only on this field regarding the solutions of its exercises.

3.2 Process – Trouble Shooting

Trouble Shooting


NOTICE:

Trouble Shooting


In the following, there is a step-by-step explanation of a sample trouble shooting. This wiring diagram is not part of the technical documentation of the Distribution Station, but show a very good example how to measure an error step by step with different measuring methods.

24

NA

/6.8

-S5

3 4

-S1

3 4

-S3

3 4

-S2

3 4

-S4

3 4

-S6

3 4

24

V/6

.8

24V

/8.1

-XK1

24V

-XK1

24N

A

0V

/6.8

0V/8

.1

2

-A2D

I1/6

.4

3

-A2D

I1/6

.4

4

-A2D

I1/6

.4

5

-A2D

I1/6

.4

CO

M/5

.7

-XM

G2

7

-XG

2O

6

-XM

G2

13

-XM

G2

14

-XM

G2

15

-XM

G2

16

-XM

G2

17

-XG

2I0

-XG

2I1

-XG

2I2

-XG

2I3

-XG

2I4

-XM

G2

21

-XG

224

VB

6

-A2D

I1/6

.4

8

-A2D

I1/6

.4

9

-A2D

I1/6

.4

7

-A2D

I1/6

.4

Disconnectionat START-Button S1

Trouble Shooting


Although the program is loaded to the PLC and normal position is reached (RESET-Light flashing) the Station may not be started (RESET-Light not change to off).

The starting condition is, that the Station is in normal position, which is indicated by flashing of the RESET-light. The reason for malfunction must be the START-button itself.

Measuring of the current path No. 1 may be proceeded in different ways. In the following, two examples may be described, and both of them are leading to result.

• measuring of voltage • measuring of continuity For better understanding, the current path No. 1 may be shown as an equivalent diagram:

0V

0V

24V

XK124V

XMG221

XMG213

A2DI12

0V-clampPLC-board

disconnection

PLCinputR

Trouble Shooting


Voltage test procedure 1. step:

0V

0V

24V

0V-clampPLC-board

PLC-inputR

0V

XK124V

XMG221

XMG213

A2DI12

Voltage test procedure 2. step:

0V

0V

24V

0V-clampPLC-board

PLC-inputR

12V

XK124V

XMG221

XMG213

A2DI12

Result: disconnection must be located between clamp XMG2 and A2DI1-2= broken wiring

Trouble Shooting


Continuity test 1. step:

0V

PLC-inputR

R>

Attention:disconnectpower supply !

no continuity

XK124V

XMG221

XMG213

A2DI12

Continuity test 2. step:

0V

Attention:disconnect power supply !

disconnection

PLC-inputR

0 continuity

XK124V

XMG221

XMG213

A2DI12

Result: disconnection must be located between clamp XMG2 and A2DI1-2= broken wiring

Trouble Shooting


The work-sheet for this example looks like:

Order of Maintenance

Name: Hellmich Order-No: 001 310800 Date: 31.08.2001

Location of Error: Distribution Station Sheet: 1 # 1

Error Detection

After switch-on theair pressure and the PLC, the RESET-light is flashing, which means, that the system is in normal position

starting condition OK

However, the station cannot be started by the Start-Button (RESET-light not change to off).

Error Limitation

MECHANICAL:

1. Is there a mechanical defect on the Start-button?

ELECTRICAL

1. Is the Start-button switching regularly? - Continuity test of switching contacts.

2. Is the signal of the button reaching the PLC? - Control by sight and voltage test.

Error Elimination

REASON

Break of wire (end sleeve) at the button at connection X.

Attach new end sleeve to the wire and connect again. Control of total sequence = error eliminated.

Planning

Please follow the description of the in instructor carefully step-by-step. Make a detailled plan of how you want to check the error location step-by-step.

Trouble Shooting



Follow the three steps of Trouble Shooting carefully. Write down the single steps and all useful informations into the work-sheet. Please show your result first to the instructor before removing the error!!!!! Please ask your instructor for copies of this work-sheets!!!

Order of Maintenance

Name: Order-No: Date:

Location of Error: Sheet:

Error Detection

Error Limitation

MECHANICAL:

ELECTRICAL

PNEUMATICAL

Error Elimination

REASON

Trouble Shooting


Controll

After error elimination, please check the process again step-by-step carefully, there might be another error within the system.

Documents

Festo