COSIMIR® PLC Manual
682526 EN 06/04
Order No.: Description: Designation: Edition: Authors: Graphics: Layout:
682526 MANUAL D:HB-COSI-PLC-EDU-EN 06/2004 Christine Löffler Doris Schwarzenberger 09.06.2004, Beatrice Huber
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2004 Internet: www.festo.com/didactic E-Mail:
[email protected] The copying, distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration.
Contents
1.
What will you learn from the manual?___________________ 7
2. 2.1 2.2
This is how you install COSIMIR® PLC _________________ 10 System requirements ________________________________ 10 Installation of COSIMIR® PLC via on-line activation ________________________________ 12 Network installation of COSIMIR® PLC __________________ 26 Installation of the communication program EzOPC ________ 28
2.3 2.4
3. 3.1 3.2 3.3
4. 4.1 4.2 4.3 4.4 4.5 4.6
These functions support you in the preparation of PC workstations for students _______________________ 29 Description of files for a process model _________________ 29 Creating a user-specific working environment ____________ 30 Creating files with fault settings for a process model _________________________________ 33
The COSIMIR® PLC system ___________________________ 37 Overview of COSIMIR® PLC ___________________________ 37 The process models of COSIMIR® PLC __________________ 39 Controlling the process models via internal PLC __________ 44 Controlling the process models via external PLC __________ 45 Functions for fault setting in the process model ________________________________ 47 Functions for the analysis of process models _____________ 48
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Contents
5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12
6. 6.1 6.2 6.3 6.4 6.5
7. 7.1 7.2 7.3 7.4 7.5 7.6
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Important control functions of COSIMIR® PLC ___________ 50 Loading the process model ___________________________ 50 Simulating the process model ________________________ 59 Displaying and operating a process model ______________ 62 Changing the view of the process model ________________ 65 The Inputs and Outputs windows ______________________ 69 The Manual Operation window ________________________ 70 Controlling a process model via the internal S7 PLC _______ 84 Controlling a process model via the external Soft PLC S7-PLCSIM _________________________________ 94 Controlling a process model via an external PLC _________ 108 Setting faults in the process model____________________ 121 Eliminating faults in the process model ________________ 129 Logging of fault elimination __________________________ 134
The following training contents can be taught with COSIMIR® PLC ____________________________________ 136 Training contents __________________________________ 136 Target group ______________________________________ 137 Previous knowledge ________________________________ 138 Example: Assigning of training aims to training syllabi ____ 138 The training concept of COSIMIR® PLC _________________ 143
This is how you establish the mode of operation and structure of a system in COSIMIR® PLC _______________ 145 Training aims _____________________________________ 145 Methods _________________________________________ 146 Support via COSIMIR® PLC __________________________ 150 Example _________________________________________ 150 Example _________________________________________ 156 Example _________________________________________ 161
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Contents
8. 8.1 8.2 8.3 8.4
This is how you establish the mode of operation of the components forming part of a system in COSIMIR® PLC __ 166 Training aims _____________________________________ 166 Methods _________________________________________ 167 Support via COSIMIR® PLC __________________________ 167 Example _________________________________________ 168
9. 9.1 9.2 9.3 9.4 9.5
This is how you use COSIMIR® PLC in PLC programming _ 175 Training aims _____________________________________ 175 Methods _________________________________________ 176 Support via COSIMIR® PLC __________________________ 178 Example _________________________________________ 178 Example _________________________________________ 185
10.
This is how you carry out systematic fault finding on a simulated system _____________________________ 193 Training aims _____________________________________ 193 Methods _________________________________________ 194 This is how COSIMIR® PLC supports you________________ 201 Example _________________________________________ 201
10.1 10.2 10.3 10.4
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1. What will you learn from the manual?
What is COSIMIR® PLC ?
COSIMIR® PLC is a PC-based graphic 3D simulation system consisting of preassembled process models. These process models represent automated systems of varying complexity. COSIMIR® PLC is a tool, which enables you • to familiarise yourself with the mode of operation and structure of a system, • to practise PLC programming and testing of the PLC programs und • to carry out systematic fault finding on systems. These process models, also called work cells, are also available in the form of actual systems.
Target group
This manual is intended for • Instructors The manual provides ideas and suggestions on how COSIMIR® PLC can be used for tuition in vocational and further training. • Teachers The information and instructions on how to operate COSMIR PLC are of particular interest to the above.
Composition of the manual
The manual is subdivided into the following subject areas: • Chapter 2 contains information and notes regarding the installation of COSIMIR® PLC . • Chapter 3 contains information on how to set up COSIMIR® PLC on students’ PC workstations. • Chapters 4 and 5 describe the system and the main user functions of COSIMIR® PLC . • Chapter 6 deals with didactic aspects and lists the training contents taught with COSIMIR® PLC . It also describes the training concept and the resulting possibilites for use in tuition.
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1. What will you learn from the manual?
•
Conventions
Additional support
Chapters 7 to 10 describe actual problem definitions regarding the training contents, the methodical approach to solutions and their realisation in COSIMIR® PLC . The exercises are for example carried out on the distribution station.
Certain print formats have been used for text as well as key combinations and sequences to enable you to find information more easily.
Print format
Meaning
Bold
This format is used for command names, menu names, dialog window names, directory names and command options.
Key1 + key2
A plus sign (+) between the key names means that you must press the keys mentioned simultaneously.
Key1 – key2
A minus sign (–) between the key names means that you need to press the keys mentioned in succession.
Additional descriptions and support are available via the on-line Help. The on-line Help comprises • COSIMIR® Help with operation and • COSIMIR® PLC Assistant. The on-line Help consists of detailed information regarding the functions and operation of COSIMIR® PLC .
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC
1. What will you learn from the manual?
This Help function is also a component part of the software package COSIMIR® Rob. COSIMIR® Rob has a wider function scope than COSIMIR® PLC and the combined on-line Help therefore describes more functions than those required for COSIMIR® PLC . The menu bar of the on-line Help provides functions that you are already familiar with from using a standard Internet browser. These include: Next and back, select start page, print selected topics, show and hide the navigation bar or Internet connection options. The additional indexes such as Contents, Index, Search or Favourites, furthermore give you the option of conveniently navigating through the information provided in the Help menu of COSIMIR® PLC . COSIMIR® PLC Assistant provides detailed function descriptions and technical documentation for the individual process models. It also comprises a sample PLC program for the more complex process models. The PLC program is created in STEP 7. All process models can be directly accessed via the graphic navigator. Adobe Acrobat Reader will need to be installed on your PC to view PDF documents. The Adobe Acrobat Reader program is available free of charge and can be downloaded via the Internet address www.adobe.com. Our telephone Hotline is available 24 hours, should you have any queries when installing or commissioning COSIMIR® PLC .
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2. This is how you install COSIMIR® PLC
With COSIMIR® PLC you have also acquired a CD-ROM and these instructions. We offer two methods for the software installation: • Network installation with dongle for parallel interface or USB interface • Installation with on-line activation.
2.1 System requirements
The system requirements for COSIMIR® PLC are specified. The system requirements for a PLC programming system are not taken into consideration. A PLC programming system is required, if you create your own PLC programs for the process models.
Minimum configuration for COSIMIR® PLC
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Processor
Pentium II 300 MHz processor or higher
Main memory
128 MB
Hard disk space
800 MB available
Operating system
Windows 98; Windows NT/2000/XP; Microsoft Internet Explorer Version 5.0 or later
Graphics card
Card with 3D acceleration and OpenGL support, 32 MB RAM
Monitor
17“ with screen resolution 1024 x 768 Pixel
Interfaces
Parallel or USB interface for dongle with network licence optional: serial interface for connection to PLC
Additional
Adobe Acrobat Reader Version 6.0 or later
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC
2. This is how you install COSIMIR® PLC
Recommended configuration for COSIMIR® PLC Processor
Pentium IV 1 GHz processor
Main memory
256 MB
Hard disk space
800 MB available
Operating system
Windows 98; Windows NT/2000/XP; Microsoft Internet Explorer Version 5.0 or later
Graphics card
Card with 3D acceleration and OpenGL support, 64 MB RAM
Monitor
19“ with screen resolution 1024 x 768 Pixel
Interfaces
Parallel or USB interface for dongle with network licence optional: serial interface for connection to PLC
Additional
Adobe Acrobat Reader Version 6.0 or later
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2. This is how you install COSIMIR® PLC
2.2 Installation of COSIMIR® PLC via on-line activation
Preparing the installation
The initial steps for installation: • Switch on the PC and start up Microsoft Windows. • Insert the COSIMIR® PLC CD-ROM. • Click onto Execute in the Start menu. • Enter d:setup.exe in the input field of the open dialog window. Confirm this entry with OK.
The start screen of the installation program is now displayed:
Follow the instructions of the installation program. If you are unsure when answering some of the questions, click onto either Back or Cancel. First, you will be familiarised with the licence agreements of Festo Didactic. You must accept these licence agreements in all instances,
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC
2. This is how you install COSIMIR® PLC
otherwise it is not possible to continue with the installation. Select Accept and then click onto the Next button.
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2. This is how you install COSIMIR® PLC
You are then offered the option of installing the software for only one registered user.
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2. This is how you install COSIMIR® PLC
In the following dialog window, you are requested to enter the product ID. The product ID is a 12-digit number, which you will find on the reverse side of the CD-ROM sleeve. If you enter an incorrect product ID, you will receive a message from the program, requesting you to enter a valid product ID.
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2. This is how you install COSIMIR® PLC
In the window Select Target Folder , define the subdirectory, in which COSIMIR® PLC is to be installed. We have selected the subdirectory C:\Programme\didactic\COSIMIR PLC as a default setting for you.
To install the program in a different directory, click onto the Search button.
Note
You should always select an installation directory, which does not contain any other versions of COSIMIR®.
You also have the option of specifying a particular program group where the COSIMIR® PLC symbols are stored. We have specified Festo Didactic for the program group as a default setting. You can of course rename this.
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2. This is how you install COSIMIR® PLC
COSIMIR® PLC is now ready for installation. Click onto Next to start the installation.
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2. This is how you install COSIMIR® PLC
Carrying out the installation
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The Start window of COSIMIR® PLC:
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC
2. This is how you install COSIMIR® PLC
You can install COSIMIR® PLC using two different options. These are: COSIMIR® extensions as well as robot and PLC languages.
We strongly recommend that you accept the preset option. The following window is displayed if you click onto the Options button to select the COSIMIR® main program:
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2. This is how you install COSIMIR® PLC
You are now advised of the successful completion of the COSIMIR® PLC installation. Now click onto Finish.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC
2. This is how you install COSIMIR® PLC
The installation of COSIMIR® PLC is complete. You now still need to decide whether you wish to carry out the licence activation immediately or at a later stage.
On-line activation
Various options are available to you for the activation of your licence:
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2. This is how you install COSIMIR® PLC
We recommend that you use the direct on-line activation as a default setting. You can however also carry out the activation from another PC. If you do not have an Internet connection, you can also request the activation code via telephone. This telephone service is available Monday to Friday from 8:00 h to 22:00 h CET. You have decided to use direct on-line activation:
You are requested to establish an Internet connection. Having done so, click onto Next and your licence will then been activated automatically. The following message will be displayed if direct communication is not possible due to Internet access protected by a firewall:
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2. This is how you install COSIMIR® PLC
The activation code is available on the relevant Internet page.
Highlight the activation code and copy it via the clipboard to the input field provided for the activation code using Ctrl+C and Ctrl+V.
Activation is complete as soon as you click onto Finish.
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2. This is how you install COSIMIR® PLC
Indirect activation
You have selected the option of carrying out the on-line activation from another PC. The following request is therefore displayed:
Now establish Internet access to the specified Internet address on another PC. The following window is then displayed:
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2. This is how you install COSIMIR® PLC
Copy the licence code to the relevant input field. Now click onto the Generate activation code button. The activation code is now displayed. Copy this code and insert it in the specified field of your installation computer.
Telephone request
You have decided to request the activation code via telephone:
Contact Festo Didactic via one of the telephone numbers listed. Quote your licence code and you will then be given the activation code for your COSIMIR® PLC software. Enter the activation code in the input field designated for this. The licence will be activated as soon as you click onto Finish.
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2. This is how you install COSIMIR® PLC
You can save the licence code and the activation code prior to completing the licence activation via Finish. To do so, click onto the Print/Copy button. You are offered various options of saving the licence code and activation code.
Multiple licence
If you have purchased a multiple licence, you will need to activate each individual installation. You will be given the relevant information during each activation as to how many licences can still be activated with the product ID quoted.
2.3 Network installation of COSIMIR® PLC
The term “network installation” refers primarily to the software licence allocation. With network installations, the software is made available via a network and a central licence server. You will need a green dongle for the network installation. The licences are allocated dynamically and can be requested from any workstation in the network up to the maximum number ordered. The licence server is a computer on the network, which performs the licence allocation. The dongle needs to be permanently inserted in the parallel or USB port during the operation of COSIMIR® PLC so that users on the network are able to permanently access the information of the dongle.
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2. This is how you install COSIMIR® PLC
Single station
You also have the option of setting up a local single station licence. Start the installation as described above. The following start screen is then displayed:
To set up a single station version, select the second option. The installation process is effected in the same as described above. If you have already completed an installation, you can subsequently make additions to the COSIMIR® PLC installation using the option Change Components.
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2. This is how you install COSIMIR® PLC
2.4 Installation of the communication program EzOPC
The software program EzOPC is required if you control the process models of COSIMIR® PLC via an external PLC. EzOPC effects the communication between the process model and the external PLC.
This is how you install EzOPC 1. Insert the COSIMIR® PLC CD-ROM. 2. Click onto Execute in the Start menu. 3. Enter d:\EzOPC\ezopc_setup.exe in the input field of the open dialog window and confirm it with OK. The start screen of the installation program is now displayed:
4. Follow the instructions of the installation program.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC
3. These functions support you with the preparation of PC workstations for students
COSIMIR® PLC consists of functions to support you in the use of the software program during training. These include: • An individual working environment that can be set up on each student’s PC. This working environment stores user specific data for COSIMIR® PLC . • Files with fault settings for a process model can be centrally set up by instructors and easily copied to the PC workstation of the students.
3.1 Description of files for a process model
The example of the distribution station process model is used to demonstrate which files belong to a process model and what information is stored in these files. The name of the directory for the distribution process model is DistributingStation.
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3. These functions support you with the preparation of PC workstations for students
File
Description
DistributingStation.mod
Process model for simulation via the internal S7-PLC.
DistributingStation.ini
Initialisations for the process model: This file contains all user specific settings for the process model such as window configuration, fault settings, etc.
DistributingStation.prot
Protocol of fault localisation: This file is read in the teacher mode and displayed in the fault log window.
DistributingStation.htm
Export of fault log: Changes in the fault localisation and in the fault log are automatically exported to these files. These files can then for instance be viewed via Microsoft Internet Explorer or Microsoft Excel.
DistributingStation.xls DistributingStation.txt DistributingStation.mcf
3.2 Creating a user-specific work environment
Settings regarding fault setting: This file contains all settings regarding the activation, start, duration and localisation of a fault. If this file exists in the process model directory, then it overwrites the settings in the INI file. If not, then the fault settings stored in the INI file are used.
User-specific working environments consist in the main of the process models and files with the user specific data. User specific data are: • Window configurations, • Settings for the process model, • Settings regarding fault setting, • Protocol of fault localisation. In order to create a user-specific working environment, the process models are saved to a separate directory on the PC. Any user specific data is then also stored in this directory.
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3. These functions support you with the preparation of PC workstations for students
For example, to set up the working environment for three different users on one PC, you will need to copy the process models into three different directories. Each user will then be working with “his/her own” directory, which corresponds to the user’s working environment. The user loads the process models with which he/she is working in COSIMIR® PLC from „his/her“ directory. COSIMIR® PLC supports you with the setting up of user specific working environments. Use the setup program SetupSamples.exe for this.
The SetupSamples.exe program The SetupSamples.exe program enables you to create the user specific working environments for COSIMIR® PLC on a PC. • The setup program SetupSamles.exe installs the process models assistant-aided on a computer or a network path. • The choice of installation directory is arbitrary. • No administrator rights on the computer are required.
This is how you create a user specific working environment for COSIMIR® PLC 1. Insert the COSIMIR® PLC CD-ROM. 2. Click onto Execute in the Start menu. 3. Enter d: SetupSamles.exe in the input field of the open dialog window and confirm this with OK. The start screen of the installation program is now displayed.
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3. These functions support you with the preparation of PC workstations for students
4. Follow the instructions of the installation program. Select the desired working directory as the installation directory. 5. If users want to work in their working environment, then they are to start COSIMIR® PLC . The process models that users are to work with must always be loaded from the user’s working directory. You can load a process model from any working directory by selecting Open in the File menu and navigating through your working directory and selecting the desired process model. Please note that file names of process models to be controlled via an external PLC always end with the identifier OPC. File names of process models controlled via the internal PLC do not end with the identifier OPC.
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3. These functions support you with the preparation of PC workstations for students
Note
You can also start the setup program SetupSamples.exe from the Windows command line (cmd.exe). To install several working environments from COSIMIR® PLC on one PC, you have the option of carrying out the installation by means of a batch file. The batch file is called up via the Windows command line. Excerpt from a batch file: SetupSamples.exe /S –XD:C:\CosimirPLC\Student1 SetupSamples.exe /S –XD:C:\CosimirPLC\Student2 SetupSamples.exe /S –XD:C:\CosimirPLC\Student3
3.3 Creating files with fault settings for a process model
Files with fault settings for a process model can be created centrally by teaching staff and copied to the PC workstations of students in a simple manner.
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3. These functions support you with the preparation of PC workstations for students
This is how you create a file centrally with fault settings for a process model: 1. Start COSIMIR® PLC . 2. Load the desired process model, e.g. the process model Distribution Station. The process model is to be controlled via the internal PLC and the file name therefore does not include the identifier OPC. 3. Open the Fault Setting window by clicking onto Fault Setting in the Execute menu. 4. The Fault Setting window opens once you have entered the password. 5. Now set a fault – for example for the PLC input 1B1. 6. Activate the context sensitive menu via the right mouse button and select the option Export.
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3. These functions support you with the preparation of PC workstations for students
7. The faults set for the process model DistributingStation.mod have been exported to the file DistributingStation.mcf. You will find this file in the same directory, in which the process model loaded at the time is also stored.
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3. These functions support you with the preparation of PC workstations for students
8. Now copy the file with the fault settings to the user specific working environments. The user specific working environments are those directories, where only the process models have been installed. Select the directory in which the relevant process model is stored as directory, in this case the Distribution Station process model.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC
4. The COSIMIR® PLC system
COSIMIR® PLC comprises the following: • The simulation software COSIMIR® PLC • The communication software EzOPC • The on-line COSIMIR® Help • The on-line COSIMIR® PLC Assistant • A PDF file with information regarding EzOPC • A manual
4.1 Overview of COSIMIR® PLC
COSIMIR® PLC is a PC-based 3D simulation system with preassembled process models.
MC7-Code
Internal S7 PLC
COSIMIR assistant Operating functions
Process models
COSIMIR help
OPC client
EzOPC
Easy Port
(OPC server)
S7-PLCSIM
External PLC
Component parts of COSIMIR® PLC
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4. The COSIMIR® PLC system
The following are required to simulate the operation of a process: • A PLC and PLC program to control the process, • The simulation to simulate the behaviour of the process. This simulation ensures for example, that cylinders move and sensors are activated. Sample PLC programs are available for complex process models. These PLC programs define a possible process control system. You can of course create new PLC programs that generate a different process execution. When loading a process model, the sample PLC program is automatically downloaded at the same time, provided that it exists. The PLC program is executed via a SIMATIC S7 simulator. This S7 simulator is a component part of COSIMIR® PLC . The integrated S7 simulator is also referred to as the internal PLC. Once the process model has been loaded, the process can be simulated immediately. The advantage with this is that you can familiarise yourself with, activate and monitor the process. Plus there is no need for you to have created a PLC program beforehand. One particular additional function offered by COSIMIR® PLC is the possibility of simulating faults, whereby you can set typical faults in a process model. The following can for example be causes of malfunction: A mechanically displaced sensor, a cable break or failure of an entire module. The cause of the fault must be found by means of systematic fault finding and eliminated. One of the main focal points of COSIMIR® PLC is the monitoring and analysis of processes and elimination of faults. Another focal point is the creation of your own PLC programs for the process models. These PLC programs are loaded to an external PLC and COSIMIR® PLC exchanges the input/output signals with the external PLC via the OPC interface.
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4. The COSIMIR® PLC system
The following can be used as external PLCs • Any actual PLC • The Soft PLC SIMATIC S7-PLCSIM COSIMIR® PLC requires the software program EzOPC for connection to an external PLC. The OPC server EzOPC communicates with any PLC via the EasyPort interface. . Please note: EzOPC is not installed automatically with the software program COSIMIR® PLC . If required, this program is to be installed from the DC-ROM provided.
4.2 The process models of COSIMIR® PLC
The process models are realistic replicas of actual working stations and modules. Each process model comprises two work cells. The work cell whose file name does not have the ending OPC is controlled via an internal PLC. If you wish to control the process model via an external PLC, you need to select the process model with the file name ending in OPC.
Process model
Description
File name
Processing Station
The process model represents a simulation of the MPS Processing Station of Festo Didactic. In this work cell, workpieces are to be tested, processed and transferred to the adjacent station. A sample PLC program is available for this process model.
ProcessingStation.mod
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC
ProcessingStation(OPC).mod
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4. The COSIMIR® PLC system
Process model
Description
File name
Handling Station
The process model represents a simulation of the Festo Didactic MPS Handling Station. In this work cell, workpieces are to be removed from a retainer and, depending on the results of material testing, deposited on a slide. A sample PLC program is available for this process model.
HandlingStation.mod
The process model represents a simulation of the Festo Didactic Stacker Store. In this work cell, workpieces are to be put into and removed from storage. A sample PLC program is available for this process model.
StoreWorkCell.mod
Stacker Store Station
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HandlingStation(OPC).mod
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4. The COSIMIR® PLC system
Process model
Description
File name
Testing Station
The process model represents a simulation of the Festo Didactic MPS Testing Station. In this work cell, the material characteristics of the workpieces is to be determined and the workpiece height checked. Depending on the test result, the workpiece is either ejected or transferred to the adjacent station. A sample PLC program is available for this process model.
TestingStation.mod
The process model represents a simulation of the Festo Didactic MPS Buffer Station. In this work cell, workpieces are to be transported, buffered and separated out. A sample PLC program is available for this process model.
BufferStation.mod
The process model represents a simulation of the Festo Didactic MPS Sorting Station. In this workcell, workpieces are to be sorted according to material and colour. A sample PLC program is available for this process model.
SortingStation.mod
Buffer Station
Sorting Station
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC
TestingStation(OPC).mod
BufferStation(OPC).mod
SortingStation(OPC).mod
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4. The COSIMIR® PLC system
Process model
Description
File name
Distribution Station
The process model represents a simultation of the Festo Didactic MPS Distribution Station. In this work cell, workpieces are to be separated out and transferred to the adjacent station. A sample PLC program is available for this process model.
DistributingStation.mod
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DistributingStation(OPC).mod
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4. The COSIMIR® PLC system
Process model
Description
File name
Rotary Indexing Table Module
The process model represents a simulation of the Festo Didactic MPS Rotary Indexing Table module. In this work cell, workpieces are to be tested and polished in two parallel sequences.
RotaryTable.mod
The process model represents a simulation of the Festo Didactic MPS Stacking Magazine module. In this work cell, workpieces are to be separated out from the magazine.
StackMagazine.mod
The process model represents a simulation of the Festo Didactic MPS Changer module. In this work cell, workpieces are to be picked up by a vacuum suction cup and transferred by means of a semi-rotary actuator.
ChangerModule.mod
Stacking Magazine Module
Changer Module
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC
RotaryTable(OPC).mod
StackMagazine(OPC).mod
ChangerModule(OPC).mod
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4. The COSIMIR® PLC system
4.3 Controlling the process models via internal PLC
The PLC integrated into COSIMIR® PLC is a SIMATIC S7 simulator. The S7 simulator can execute LDR, FCH and STL programs created in STEP 7. The internal PLC executes the sample PLC programs provided for the process models and enables you to immediately simulate the processes. Detailed information regarding the function scope of the internal PLC is available via the COSIMIR® on-line Help.
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4. The COSIMIR® PLC system
4.4 Controlling the process models via external PLC
If you are creating and testing your own PLC programs, we recommend that you download the programs to an external PLC and execute them from there. The advantage of this is that you can choose the PLC and programming system of your choice. Also, the testing and diagnostic functions designated by the program for this purpose are available to you for fault finding in the PLC program. This includes the status display of PLC input/outputs and variables, the on-line display of the PLC program and also the read-out of machine statuses. If you are using the Soft PLC7-PLCSIM as external PLC, you do not require any additional hardware components.
Information exchange with configuration via external Soft PLC S7-PLCSIM
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4. The COSIMIR® PLC system
If you are using a hardware PLC as external PLC, you will require EasyPort and the data cable for the exchange of input/output signals. EasyPort transmits the input/output signals of the PLC to the OPC server ExOPC via the serial interface of the PC and the OPC server passes on the data to the process model simulation. Conversely, the statuses of sensors and actuators are communicated from the process model to the external PLC.
Information exchange with configuration via external hardware PLC
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4.5 Functions for fault setting in the process model
The dialog window for fault setting is password protected. Only instructors have access to this dialog. A list of typical faults is available for each process model, from which you can select one or several faults.
The exercise for students is to identify and describe the fault within the process and to then determine the cause of it. The students then enter the suspected fault in the dialog window for fault elimination. If the fault has been correctly identified, the process will then function correctly. The entries in the dialog window for fault elimination are logged and can be seen by instructors and trainers.
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4.6 Functions for the analysis of process models
COSIMIR® PLC offers you various options of monitoring and analysing the execution of a process. As soon as the simulation of a process model is active and a PLC is controlling the process, you can activate and visually monitor progress. The process is controlled by means of the keys and switches on the control console.
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• • • •
The electrical status of the process components is displayed by LEDs on the sensors and valves. If pressure is applied to a cylinder connection, the connection is highlighed in blue. The pneumatic tubing itself is not simulated. The statuses of the PLC inputs/outputs are shown in separate windows. An overview of all process statuses and process operations is provided in the Manual Operation window.
If you want to run the process step-by-step, you need to use the Manual Operation as a tool to control the process. You can stop the process at defined points by setting breakpoints. In the absence of an active PLC program during process model simulation, you can use the Manual Operation window to activate individual process activities. This will enable you to, for instance, control the movement of a cylinder or switch on or off an electrical motor.
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This chapter describes the main control functions of COSIMIR® PLC . MS Windows programs provides various options for activating commands. In this account, commands are initiated via the options in the menu bar. You can of course also use the symbols bar, appropriate key combinations or the context sensitive menu via the right mouse button. Detailed information regarding the use of all options in COSIMIR® PLC is available via the on-line Help for this software package.
5.1 Loading a process model
Prior to loading a process model, you will need to decide whether the process model is to be controlled via the internal or via an external PLC. The file names of process models to be activated via an external PLC end with the identifier OPC. You can load the process model with the help of COSIMIR® PLC Assistant or a command in the menu bar.
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This is how you load a process model via COSIMIR® PLC Assistant 1. Start COSIMIR® PLC . Once COSIMIR® PLC is started, both the View window and the Help window are displayed.
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2. Select the desired process model, for example the process model Distribution, controlled via the internal PLC. The process model is opened by clicking onto Open Distribution (for internal PLC). Please note: A click onto the picture or the title of the process model will take you to COSIMIR® PLC Assistant, where a function description and technical documentation regarding the process model are at your disposal.
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3. The process model for the Distribution station is loaded and is displayed in the View window. In addition, you will also find the status of the PLC input/outputs in the Inputs and Outputs windows.
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Note
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A dialog window is displayed via File download, if you open a process model the first time via the on-line Help.
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If you select the option Open File from your Current Position, you need to deactivate Always Confirm Open Files of this Type and click OK.
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This is how you load a process model by activating a menu command 1. Click onto Open in the File menu. The process models are filed under the default setting c:\Programme\didactic\COSIMIR PLC \samples. Each process model is in its own subdirectory.
2. Select the desired process model, for example the process model Distribution, controlled via the internal PLC. To do so, open the subdirectdory DistributingStation: Highlight the directory DistributingStation and click onto the Open button.
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3. Highlight the file DistributingStation.mod and click onto the Open button.
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4. The process model for the Distribution station is now loaded and is displayed in the View window.
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5.2 Simulating a process model
Once loaded, the process is displayed, but simulation is not active.
If a process model, controlled via the internal S7 PLC, has been loaded, a sample PLC program will have been downloaded to the internal S7 PC at the same time. This is essential to facilitate the operation of a process model. As soon as simulation is active, you can monitor the visual simulation and as such the function sequence of the process model in the activity window.
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Certain information is always available to you. In the header you will see the file name with path details of the process model loaded. The status line informs you of the operational status of the process model: The field to the far left shows whether simulation is active or stopped. • Stopped: Simulation mode is not active. The process model is not simulated. • Cycle: The process model is simulated. • Sequence: The process model is simulated. The field to the right indicates the simulation time.
Note
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In COSIMIR® PLC , both simulation modes Cycle and Sequence are identical.
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This is how you switch simulation on and off again 1. Click onto Start in the Execute menu. Simulation is active. In the status bar, the simulation mode is displayed via Sequence. Alternatively, you can also activate simulation via the menu option Start Cycle or via the Stopped button in the status bar.
2. You can stop simulation by clicking onto Stop in the Execute menu. Alternatively, you can also click onto the Cycle field.
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5.3 Displaying and operating a process model
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A process model controlled via a PLC program is operated via the keys and switches of the control console. To do so, simulation must be active. The simulation status can be established via the information in the status bar.
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This is how you operate a process model controlled via the sample PLC program 1. Start simulation by clicking onto Start in the Execute menu. 2. The illuminated Reset button now requests the Reset function. Failing this, put the process model into the initial position. To do so, activate the simulation. Then click onto the command Work Cell Initial Position in the Processing menu. Now restart simulation. 3. Carry out the Reset function by clicking onto the Reset button. 4. The illuminated Start button indicates that the process model is in the initial position and the start condition is fulfilled. 5. Make sure that workpieces are available. For the process model Distribution, you fill the magazine with workpiece by clicking onto the different coloured symbolic workpieces on the slotted assembly board. 6. Start the cycle by clicking onto the Start button. If the process model is to be controlled via your own PLC program, then you will know how the process and operation are defined. If the process model is not controlled via a PLC program, then you can manually activate specific actuators of the process. You will need the functions of the Manual Operation window for this.
This is how the status of the process model is displayed • The electrical status of the process components is displayed via the LEDs on the sensors and valves. • If pressure is applied to a cylinder connection, then this connection is highlighted in blue. The pneumatic tubing itself is not shown. • The status of the PLC signals is displayed in the Inputs and Outputs windows. • The Manual Operation window provides an overview of all process statuses and process events.
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The designation of components is shown by clicking onto the connection or LED of a process component. This designation is identical to the designation in the circuit diagram. An exception to this are the designations of compressed air connections. These pertain to the valves which supply the compressed air connections with air.
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5.4 Changing the view of a process model
The perspective view of a process model is freely adjustable and you can turn, move, enlarge or minimise the process model representation by means of a few central commands.
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The perspective view is defined by the coordinates of the viewer (= angle) and a reference point of the process model (= centre).
Reference point Z
Angle
Turn
Y
X
Definition of perspective view
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This is how you move the process model 1. Click onto the Move command in the View menu. This changes the mouse pointer into a small coordinate system, which indicates the direction in which the angle and reference point can be moved. A dashed arrow means that it is not possible to move in the respective direction. 2. Hold down the left mouse button. 3. Move the mouse pointer in Z- or X-direction. 4. Release the mouse pointer again. The view will then change accordingly. You can also activate the Move command by holding down the Shift key and pressing the left mouse button.
This is how you turn the process model 1. Click onto Turn in the View menu. The mouse pointer now changes into a small coordinate system, which indicates the direction in which the angle and reference point can be moved. A dashed arrow means that it is not possible to move in the respective direction. 2. Hold down the left mouse button. 3. Move the mouse pointer in Z-or X-direction. 4. Release the mouse pointer again. The view will then change accordingly. You can also activate the Turn command by holding down the Ctrl key and then pressing the left mouse button.
This is how you enlarge or minimise the view 1. Activate the Zoom command in the View menu. The mouse pointer now changes into two squares. 2. To enlarge the view, hold down the left mouse button and move the mouse pointer in the direction of the arrow.
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3. To reduce the view, hold down the left mouse button and move the mouse pointer in the opposite direction of the arrow. You can also activate the Zoom command by holding down the Shift + Ctrl key combination and then pressing the left mouse button.
This is how you enlarge a particular section 1. Position the mouse pointer on a corner of the section. 2. Hold down the Shift + Ctrl key combination. 3. Press the right mouse button and move the mouse. A frame is then displayed. 4. Place the frame around the section you would like to enlarge by moving the mouse. 5. Release the right mouse button. The view is now enlarged.
This is how you enlarge the view Click onto Zoom-In in the View menu. The image is now enlarged to 125%.
This is how you minimise the view Click onto Zoom-Out in the View menu. The picture is minimised to 80%.
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5.5 The Inputs and Outputs windows
The Inputs and Outputs windows indicate which signals are applied at the inputs and outputs of the PLC. 0-signals are displayed in red and 1-signals in green. If the input or output signal is forced, the value is shown in angle brackets, e.g. .
This is how you open the Inputs window Click onto the option Inputs/Outputs in the Options menu and select Display Inputs. So that you know which process signal you are dealing with, the signal names include the relevant designation from the circuit diagrams. Example: STATION_1B2: PLC input, which is connected to the sensor 1B2.
This is how you open the Outputs window Click onto the option Inputs/Outputs in the Options menu and select Display Outputs. So that you know which process signals you are dealing with, the signal names contain the relevant designations from the circuit diagrams. Example: STATION_1Y1: PLC output, which is connected to the valve coil 1Y1.
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Notes
You can however also open the Inputs and Outputs windows via Work Areas in the Windows menu, where you will often find the required window combinations.
5.6 The Manual Operation window
The Manual Operation window offers various functions • Display of process statuses and process activities, • Controlling individual actuators of the process model, • Setting breakpoints in the process model simulation.
In the lefthand section of the window you can see the process activities. These include mainly the actuation of valves. An applied 1-signal is represented by a red illuminated LED. In the righthand section of the window you can monitor all process statuses. Process statuses include the status of the sensor and valve coils. Here, 1-signals are represented by a green illuminated LED. The signal statuses are also shown in the Value column. If the signal is forced, the value is shown in angle brackets. If the Value column is now shown, activate the item in the context sensitive menu via the right mouse button.
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The following additional information is displayedi: If a signal status has changed since the last simulation cycle, then the respective line is highlighted in colour. Process activities are shown in red and process statuses in green. This method enables you to easily identify and track any signals which have changed.
This is how you open the Manual Operation window In the Execute menu, click onto Manual Operation. Alternatively , open the window by clicking onto Manual Operation under Work Areas in the Windows menu.
This is how you control individual actuators in the process model If you want to actuate individual actuators of a process model manually, we recommend that you disconnect the process model from the PLC. Only those commands will then be executed which have been initiated via manual operation since the PLC program is no longer active. If you wish to terminate manual operation and control the process model via a PLC program once again, you will need to reconnect the process model to the PLC.
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1. Make sure that simulation is stopped. 2. Isolate the process model from the PLC. Move the mouse pointer to the left section of the Manual Operation window and the process activities. Press the right mouse button to open the context sensitive menu and select Disconnect Controllers. Or:Click onto the left section of the Manual Operation window and open the context sensitive menu via the right mouse button and then select Disconnect Controllers.
3. Start the simulation.
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4. Double click onto the process activity line you wish to execute. The double click causes the signal to change. If you double click onto a line with a valve activation, this causes the value of the respective valve coil to change. If the value 0 is applied, this will be set to 1 or vice versa. The double click therefore has a toggle function. Please note: To switch a valve with two valve coils to a particular position, the appropriate electrical signal must be applied to both valve coils.
5. Stop simulation, if you wish to end Manual Operation.
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6. To control the process model via a PLC program again, move the mouse pointer to the left section of the Manual Operation window to the process activities. Now press the right mouse button to open the context sensitive menu and select Restore I/O Connections.
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This is how you set breakpoints during the operation of the process model To stop the process model operation at defined points, you will need to set breakpoints in the process model simulation. You can stop the process run whenever the value of a process signal is changing. Breakpoints merely influence process model simulation; the PLC program for the control of the process model remains unaffected. If a breakpoint is set at a signal, this causes the process model simulation to stop when the value of the signal changes. The changed value is transmitted to the PLC as soon as simulation is restarted. 1. Make sure that a process model is loaded. 2. Start the process model simulation and establish that the process model is controlled via a PLC program. 3. Open the Manual Operation window. To do so, click onto Manual Operation in the Execute menu.
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4. Click onto the line of the desired process activity. In this case, for example, line 2 to control valve coil 1Y1 for the magazine ejector. Click onto the right mouse button to open the context sensitive menu and select Stop at Value Change.
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5. The Stop sign in the line in the Manual Operation window indicates that a breakpoint is set at this signal.
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6. Activate the process. As soon as the PLC generates a 1-signal at the valve coil, simulation stops. You can follow the simulation status in the status bar.
7. If you restart simulation of the process model, this causes the process run to continue and the magazine ejector to eject a workpiece.
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8. To delete the breakpoint, click onto the line with the breakpoint with the right mouse button. This opens the context sensitive menu of the right mouse button. Select Stop at Value Change. This command is realised in the form of a toggle function. The breakpoint is removed. Alternatively, you can select the command Delete all Stops.
Please note that you can also set breakpoints at signals in the Process Status window section.
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This is how you control the process model step-by-step If you want to execute the process stepwise, then use the Manual Operation window as a tool to control simulation. You can stop the process at defined points by setting breakpoints. To execute the process step-by-step, set breakpoints against all process activities. In this way, the process will be stopped whenever an actuator changes its status. 1. Make sure that a process model is loaded. 2. Start the process model simulation and make sure that the process model is controlled via a PLC program. 3. Open the Manual Operation window. To do so, click onto Manual Operation in the Execute menu.
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4. Under Process Activities, highlight all lines containing signals for valve coils by pressing the Ctrl key and clicking onto the desired lines with the left mouse button. Open the context sensitive menu via the right mouse button and select Stop at Value Change.
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5. All lines with valve coils now indicate breakpoints.
6. Control the process by using the keys and switches of the control console. Whenever the status of a process signal changes, simulation stops. The process is continued if you restart simulation.
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7. To remove the breakpoints again, open the context sensitive menu via the right mouse button and select Delete all Stops.
Please note that you can also set breakpoints at signals in the Process Status window section.
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5.7 Controlling a process model via the internal S7 PLC
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The internal S7 simulator interprets executable S7 programs. A sample PLC program for S7-300 is available for each of the more complex process models. When you load a model, the respective S7 program is also downloaded. You can exchange this S7 program with another S7 program, if required. Only complete project files with the file extension S7P can be downloaded. The project will need to have been created via the SIMATIC Manager and must be in accordance with the Siemens MC7 code at binary level.
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This is how you control a process model via the relevant sample PLC program 1. Click onto Open in the File menu. 2. Load the desired process model, for example the Distribution process model. The file name of the model is DistributingStation.mod. The process models are stored under a default setting c:\Programme\didactic\COSIMIR PLC \samples. When a process model is loaded, the respective S7 program is also downloaded.
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3. As soon as simulation of the process model is started, the execution of the S7 is also started. To do so, click onto Start in the Execute menu.
This is how you control a process model via a newly created S7 PLC program 1. Load the desired process model. The process model is to be controlled via the internal PLC. The file names of process models for the internal PLC do not end in OPC.
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2. Make sure that simulation has stopped. 3. Select Open in the File menu to open the Open File window. 4. Under File Type, select S7 Project (*.S7P). All files of this format available in the current directory are displayed.
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5. Navigate to the directory which contains your S7 project. Select the required S7 project and click onto the Open button.
6. If the project you have selected contains several S7 programs, then select one for simulation and confirm your choice with OK.
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7. Start the process model simulation. Select Start in the Execute menu. As soon as the simulation of the process model is started, the internal S7 simulator is also started and the loaded PLC program is executed.
This is how you estalish which S7 program is currently loaded 1. Click onto the S7 Program Manager option in the Execute menu. 2. The name and the structure of the PLC program are displayed in a clearly set out tree structure. The PLC program may consist of the following blocks: Organisation blocks, function blocks, data blocks, functions and system functions.
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3. Click onto the +-symbol to display the PLC program. You can view the contents of a block by clicking onto a block.
4. In the absence of a loaded PLC program, the window S7 Program Manager looks as follows:
Further information regarding the display of S7 programs in STL or for the display and use of timing diagrams is available via the on-line Help.
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This is how the sample programs are filed on the computer 1. Select Open in the File menu to open the Open File window. 2. Under File Type, select S7 Project (*.S7P). All the files in this format available in the current directory will be displayed.
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3. Navigate to the directory c:\Programme\didactic\COSIMIR PLC\samples\S7\MPSC. This directory contains the S7 project with all the sample PLC programs for the stations, provided that you have transfered all the preset directories when installing COSIMIR® PLC . The sample program for the stacker store is stored in the Store subdirectory.
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4. Select the S7 project and click onto the Open button.
The program name provides information about the PLC program and the process model to which it belongs: • The initial digit corresponds to the station number. • The two letters after this digit designate the station: DI: Distribution station TE: Testing station PR: Processing station HA: Handling station BU: Buffer station SO: Sorting station • The letters beginning with underscore designate the programming language of the PLC program: AS: Programming language GRAPH, KFA: Programming languages LDR, FCH and STL, KFAFF: Programming languages LDR, FCH and STL. The step structure of the process activity is simulated with flipflops. Please note that the internal S7 PLC can only execute LDR, FCH or STL programs.
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5.8 Controlling a process model via the external Soft PLC S7-PLCSIM
S7-PLCSIM is a Soft PLC, which executes the PLC programs created in STEP 7. Within STEP 7, comprehensive testing and diagnostic functions are available to you for fault finding in the PLC program. They include, for instance, the status display of variables or the on-line display of the PLC program. You can make use of these functions when creating the PLC program for a process model in STEP 7 and subsequently when testing the PLC program during interaction with the process model. The exchange of the PLC input/output signals between the process model simulation and the Soft PLC S7-PLCSIM is effected via the EzOPC program. EzOPC must be installed on your computer. Should this not be the case, you will need to carry out the installation of the COSIMIR® PLC CD-ROM now.
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Following successful installation, EzOPC is automatically called up by COSIMIR PLC as soon as you start the process model simulation. The following requirements must be fulfilled in order for the PLC input/output signals to be correctly exchanged: • When EzOPC is started, both communication users – S7-PLCSIM and the process model simulation- must already be active. Only then can EzOPC set up the communication link to both stations. • The EzOPC must be correctly configured for the data exchange. Therefore check the configuration as soon as EzOPC is started.
Configuration of EzOPC for data exchange with S7-PLCSIM
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This is how you control a process model with S7-PLCSIM 1. Start STEP 7 or the STEP 7 Manager and open the required S7 project. 2. Start S7 PLCSIM by clicking onto Simulate Modules under Options.
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3. The S7-PLCSIM window now opens.
4. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto the MRES button in the CPU 300/400 window.
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5. Download the desired PLC program in S7-PLCSIM by highlighting the Modules folder. Then click onto Download in the menu Target System.
6. Load the appropriate process model in COSIMIR® PLC . The file name of the process model must end in OPC, since it is to be controlled via the external PLC S7-PLCSIM.
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7. Start the process model simulation by clicking onto Start under Execute. As soon as simulation starts, the EzOPC program is automatically called up and you will see this from the item EzOPC displayed in the Start bar. If EzOPC is not called up, you will need to check whether the program is installed. Failing this, now carry out the installation.
Note
When EzOPC is started, both communication users - S7-PLCSIM and the process model simulation – must already be active. Only then are the communication links correctly set up.
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8. Click onto the EzOPC button in the Start bar. This opens the EzOPC window, where you configure the communication between COSIMIR® PLC and S7-PLCSIM. The EasyPort D16 interface is crossed out. This indicates that the communication link between EasyPort and EzOPC does not exist.
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9. Click onto Communication Setup under Configuration.
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10. The window Communication Setup is now displayed.
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11. Carry out the necessary settings. Select Not Connected in the EasyPort section for EasyPort 1. Now select Installed in the section PLCSIM for Step 7 PLCSIM V5.x. Accept the preset values for Start Byte and End Byte without changing them, although only the first four bytes are required. In the section VirtualPLC, select PLCSIM for Connect VirtualPLC to: and confirm the settings with OK.
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12. The changes require EzOPC to be restarted. Acknowledge this message with OK.
13. Close the EzOPC program and restart it. You will find EzOPC under the default setting Programs Festo Didactic EzOPC V4.9.2 .
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14. EzOPC displays the new configuration: – EzOPC does not use the serial interface. – EzOPC has set up a communication link with S7-PLCSIM. The data bytes from S7-PLCSIM shown are exchanged.
15. Minimise the EzOPC window. 16. Make sure that the process model simulation in COSIMIR® PLC is active.
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17. Start S7-PLCSIM by clicking onto the box next to RUN in the window CPU 300/400. The LED for RUN should now start flashing.
18. Operate the process model as planned and programmed in the PLC program.
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19. If faults still exist in the PLC program, then the on-line representation in STEP 7 will provide you with excellent support during fault finding. To do so, call up the program block in which you suspect the fault. Then click onto Monitor in the Test menu. You can now monitor in parallel with simulation, which PLC program sections are or are not being executed.
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5.9 Controlling a process model via an external PLC
If you are creating and testing your own PLC program, we recommend that you load the programs to an external PLC and have these executed from there. You can use the Soft PLC S7-PLC SIM as external PLC, if you are programming in STEP 7, in which case you will not require any additional hardware components. You can however also use any other control or programming system, in which case you download the PLC program to your hardware PLC. The exchange of the PLC input/output signals between the process model simulation and your external PLC is effected via the serial interface of the PC and via the EasyPort interface. Also included in the exchange of process signals is the EzOPC program. The advantage of this configuration is that you can use the PLC and programming system of your choice. Also available for fault finding in the PLC program are the testing and diagnostic functions intended for this purpose in the programming system. We recommend that you install the simulation software COSIMIR® PLC and the PLC programming system on different computers.
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Possible configuration with a hardware PLC and two PCs
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However, you can also choose a different configuration and install the two software packages on one PC. Your PC will need to be equipped with two serial interfaces if you intend to make use of the testing and diagnostic functions during the process model simulation . The following can be used as EasyPort interface: • EasyPort D16 interface box for 16 digital I/O (Order No.. 1676 121) The following data cables are required: • PC data cable RS232 (Order No. 162 305) • For PLC EduTrainer of Festo Didactic: I/O data cable with SysLink plugs at both ends to IEEE 488, cross paired (Order No.. 167 106) • For any PLC: I/O data cable with SysLink plug at one end to IEEE 488 and open cable end sleeves (Order No. 167 122)
The EzOPC program The EzOPC program organises the exchange of PLC input/output signals between the process model simulation and the external PLC. EzOPC does not access the external PLC signals directly, but via the EasyPort interface. EzOPC must be installed on your computer. If this is not the case, you will need to install the COSIMIR PLC CD-ROM now. Once the installation has been successfully completed, EzOPC will be automatically called up by COSIMIR PLC as soon as you start the process model simulation.
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The following requirements must be fulfilled in order for the PLC input/output signals to be correctly exchanged: • When starting EzOPC, both communication users – EasyPort and the process model simulation - must be active. Only then can EzOPC set up the communication link to the two users. In the case of EasyPort this means that EasyPort must be connected to the PC via the serial interface and voltage applied to EasyPort. • The EzOPC program must be correctly configured for the data exchange. Therefore check the configuration as soon as EzOPC is started.
Configuration of EzOPC for data exchange with an external PLC via EasyPort
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This is how you control a process model via an external PLC 1. Connect the PC with COSIMIR® PLC to the external PLC via the EasyPort interface. – The data cable with Order No. 162 305 connects the serial interface of the PC to the serial interface RS232 of EasyPort. – The PLC input/output signals for the process are applied at port 1 of EasyPort. – The PLC input/output signals for the control console are transmitted via port 2. For the DIP switches under Mode at EasyPort, select the following setting: 1 ON, 2 OFF, 3 OFF.
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Configuration with PLC EduTrainer
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Configuration with PLC board
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2. Switch on the power supply for EasyPort. 3. Load the desired process model to COSIMIR® PLC . The file name of the process model must have the ending OPC, since it is to be controlled via an external PLC. 4. Start the simulation of the process model by clicking onto Start under Execute. The EzOPC program is called up automatically when simulation starts. You will see EzOPC displayed in the Start bar. If EzOPC is not shown in the Start bar, you need to install it now from the COSIMIR® PLC CD-ROM.
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Note
When EzOPC is started, both communication users - EasyPort and the simulation of the process model – must already be active. Only then can the communication link be correctly set up. 5. Click onto the EzOPC button in the Start bar to open the EzOPC window, where you configure the communication between COSIMIR® PLC and EasyPort.
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6. Carry out the settings for the serial interface. To do so, click onto Serial Interface in the Configuration menu.
7. Under COM Port , enter the serial interface of your PC, to which EasyPort is connected and confirm this setting with OK.
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8. Under Configuration, click onto Communication Setup.
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9. This opens the Communication Setup window.
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10. Carry out the necessary settings. Select the entry EasyPort in the section VirtualPLC for Connect VirtualPLC to: and confirm this with OK.
11. Minimise the EzOPC window. 12. Download the PLC program to the PLC. 13. Start up the PLC. 14. Start the process model simulation. 15. Operate the process model according to how you have planed and programmed it in the PLC program.
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5.10 Setting faults in a process model
Use the Fault Setting window to set specific faults in the functional sequence of a process model. Use the internal PLC and the sample PLC program provided to control the process model. This ensures that a potential fault behaviour is caused solely by process components. The PLC program is operating error-free. The setting of faults is permissible by authorised users only. This is why the dialog for fault setting is password protected. The default for the password is didactic. The password can be changed at any time. Each process model contains a list of possible faults.
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The following data is required if you want to generate a fault for one of the listed process components • Type of fault • Start of fault • Duration of fault With some components, different faults can occur and you can select these faults from a list of options. The following mean: • Reed switch displaced: Reed Switch is mechanically displaced. • Reed switch jammed: A 1-signal is continually applied at the reed switch. • Cable break: A 0–signal is continually applied at a component. • Short circuit - voltage: A 1-signal is continually applied at component. • Malfunction: Complete failure of component. • Tubing defective: Pneumatic tubing is defective, operating pressure not achieved. • Compressed air supply malfunction: Pressure failure. • Power supply malfunction: Voltage not available. The time stated for the start of malfunction refers to the simulation time after the fault is set. The duration of the fault is to be indicated in seconds. Error statuses influence the simulation of the process model as soon as the Fault Simulation is active. The fault function remains active even if COSIMIR® PLC is terminated or restarted. It remains active until it is deactivated in the Fault Setting window.
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This is how you set faults in the process model 1. Make sure that a process model is loaded. The process model is to be controlled via the internal PLC. 2. Open the Fault Setting window by activating Fault Setting in the Execute menu.
Note
You can also open the Fault Setting via Window Workspaces Teacher mode. Under Teacher mode are frequently-needed window combinations for the Fault operation.
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3. A dialog box is displayed for the password to be entered. Enter the password. Provided that you have not changed the password since COSIMIR® PLC has been installed, then the standard specified password is still valid. Enter didactic in the Password box. Note that the password is case-sensitive. Confirm your entry with OK.
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4. The Fault Setting window is now displayed.
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5. Set a fault function – for example for the PLC input 1B1. Double click onto the appropriate field in the Type column to display a list of options. Open the list and select the type of fault, e.g. Cable break. The fault is to become active with the start of simulation and to remain so until the fault is cancelled in Fault Setting. No entry is therefore required in the Begin column field. The duration of the fault is arbitrary and likewise, no entry is therefore required in the Duration column. Entries in the Begin and Duration column are activated by means of a double click.
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6. The selected faults are displayed in the Status column.
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7. Now activate the Fault Simulation mode by selecting Fault Simulation in the Execute menu.
8. Close the process model in order to deactivate the teacher mode.
This is how you start the simulation of the process model with the set faults 1. Open the process model with the set fault. 2. Make sure that Fault Simulation is activated. 3. Start the process model simulation.
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5.11 Eliminating faults in a process model
Use the Fault Localisation window to eliminate error functions in the process model. The set error functions only occur if the process model is controlled via a PLC program and if the Fault Simulation mode is active.
Example
Distribution process model: The process activity stops once a workpiece is ejected. The next step, moving the swivel arm into the magazine position, is not executed. When monitoring and analysing the process model simulation, you realise that voltage is applied to the sensor 1B1, but not to the respective PLC input. You therefore conclude that there is a cable break at the PLC input 1B1.
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This is how you eliminate a fault in the process model 1. Make sure that the process model is loaded. 2. Open the Fault Localisation window by clicking onto the Fault Localisation window in the Execute menu.
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3. The Fault Localisation window is displayed.
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4. In the line 1B1 PLC input, double click onto No fault and select Cable break in the list. The button is now illuminated in yellow. If the fault Is correctly identified, the next process model simulation will be executed fault-free.
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5. In teacher mode, the Fault Localisation window looks as follows:
Note
• • •
If you have correctly identified and entered the fault, the process model is executed correctly in the next simulation cycle. If you have failed to correctly identify the cause of the fault, then the fault remains in place. If you have erroneously identified the cause of the fault as a mechanically displaced sensor, then you have created an additional fault within the process as a result of this and the fault is active from the next simulation onwards.
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5.12 Logging of eliminated faults
Each action in the Fault Localisation window is logged in a log file. Authorised persons are able view the log file.
The log file contains a list of activities which have been listed in the Fault Localisation window. The entries contain the following data entered by the student. • Date • Time Faults, which have been correctly identified and eliminated are marked in green.
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This is how you access the log file 1. Open the Fault Log window by activiating Fault Log in the Execute menu. 2. A dialog box is then displayed for you to enter the password. Enter the password. Provided that you have not changed the password since COSIMIR® PLC has been installed, the the standard specified password is still valid. Enter didactic in the Password box. Please note that the password is case-sensitive. Confirm your entry with OK.
3. The Fault Log window is now displayed.
Notes
To cancel the fault log, activate the context-sensitive menu via the right mouse button and select the appropriate command.
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6. The following training contents can be taught with COSIMIR® PLC
COSIMIR® PLC is a multimedia training aid for use in the field of automated systems. The examples given represent practice-related applications. The exercises are based on industrial process sequences and aim to portray a holistic training process. With COSIMIR® PLC , you will be training in both methodology and professional competency.
6.1 Training contents
COSIMIR® PLC provides process models for systems of varying complexity from the production sector. The general training aims to be achieved with COSIMIR® PLC are to be able to • Analyse and understand the mode of operation and system structure of PLC controlled systems, • Create and test PLC programs or clearly configured systems and • Carry out systematic fault finding as part of maintenance and corrective maintenance. These general training aims cover all subject areas that can be taught by means of simulated processes. The main focus of training is on a methodical approach.
Significance of the training contents in industrial practice One of the most important influences in industrial development over the past few years has been the ever increasing degree of automation, growing complexity of processes and faster operating cycles. The keywords here are optimal utilisation of high investment, flexible and cost effective production. More specifically these include: • High degree of machine efficiency, • Less downtimes, • Optimisation of systems, • Continual improvement processes.
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As a result of this, those who are dealing directly with a system are to some extent faced with entirely new demands. A system operator now takes on minor maintenance work and possibly some corrective maintenance, as does the installer. A mechanical maintenance engineer must have sufficient knowledge and understanding of electrical and electronic control technology to draw the necessary conclusions regarding pneumatics, hydraulics and mechanics. Conversely, an electrical engineer requires knowledge about pneumatic and hydraulic actuators. At the same time, these changing requirements lead to new forms of collaboration. Grouped together, these requirements can be put into three areas • Technology know-how • System know-how and system understanding • Socio-cultural skills With COSIMIR® PLC you will develop your knowledge and practice your skills in the areas of technology know-how as well as system know-how and understanding. Apart from technical know-how, these skills also include decision-making responsibility and methodological compentency .
6.2 Target group
The target group for COSIMIR® PLC includes all those whose professional area of activities involves PLC programming, maintenance and corrective maintenance or those who need to have a basic knowledge on these topics. These include: • Professional teachers/instructors – Mechatronics engineers – Electrical engineers, for instance specialising in automation technology – Industrial mechanical engineers • Professional qualifications in metal-working and electrical engineering • Vocational training at colleges and universities
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6.3 Previous knowledge
Knowledge is required of the following in order to work and train with COSIMIR® PLC : • A basic knowledge of control technology: Structure of an automated system • A basic knowledge of PLC technology: Design and mode of operation of a PLC • A basic knowledge of PLC programming and handling of a PLC programming tool, such as the programming system SIMATIC STEP 7 • A basic knowledge of pneumatic control technology: Drives, control elements • A basic kowledge of sensor technology: Limit switches, contactless proximity sensors • A basic knowledge of designing, wiring and tubing of electropneumatic systems. • A basic knowledge of electrical engineering: Electical variables, correlations and calculations thereof, direct and alternating current, methods of electrical measurement • Basic knowledge of how to read and interpret circuit diagrams • The ability to deal with and operate Windows programs
6.4 Example: Assiging training aims to training courses
Below is a list of training aims on the subjects of system know-how, PLC programming and systematic fault finding. The training aims are taken from the 1999 sillabus for mechatronics engineers. The contents have been adapted and weighted accordingly such as for instance for the 2003 syllabi for electronic engineers. Mechatronics and electronics engineers are two examples of how vocational training in Germany is currently updated and adapted to the new training area concept. The tables below list only those training aims which can also be taught with COSIMIR® PLC.
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Training content: Analysis of mode of operation and structure of a system
Mechatronics engineer Area of training
Training aims
Area of training 1: Analysis of functional interrelationships within mechatronic systems
To read and use technical documentation. To have a command of processes in order to be able to analyse and document functional interrelationships. To draw up and interpret block diagrams. To identify the signal, material and energy flow with the help of technical documentation.
Area of training 4: Investigating the energy and information flow in electrical, pneumatic and hydraulic modules
To understand basic control technology circuits: To actuate (pneumatically and hydraulically) a single-acting and double-acting cylinder, basic logic operations, contactor circuits, digital circuits. To read and use circuit diagrams. To identify power supply units in electrotechnology, pneumatics and hydraulics. To identify and describe the control functions of simple control systems. To design a control system (block diagram). To identify signals & measured values in control systems.
Area of training 7: Realisation of mechatronic subsystems
To understand and describe mechatronic subsystem structures. To understand and analyse the mode of operation, signal behaviour and the use of components (sensors and actuators). To understand basic circuits and the mode of operation of drives.
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Mechatronics engineers (continuation) Area of training
Training aims
Area of training 8: Design and construction of mechatronic systems
To describe the structure and signal pattern of mechatronic systems.
Area of training 9: Analysing the information flow in complex mechatronic systems
To describe the information structure (signal structure, signal generation, signal transmission) of a system with the help of circuit diagrams.
To analyse the effect of changing operating conditions on a process cycle.
To establish the interrelationship between electrical, pneumatic and hydraulic components. To analyse signals (binary, analogue, digital) and to deduce potential error sources. To use computer-aided diagnostic methods, e.g. testing and diagnostic functions of a programming system or bus system. Area of training 11: Commissioning, fault finding and corrective procedures
To analyse mechatronic systems on the basis of technical documentation and to break down their configuration into function blocks.
Area of training 13: Handover of mechatronic systems to customers
To describe mechatronic systems.
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To create operating instructions and documentation.
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Training content: PLC programming and testing of the program
Mechatronics engineers Area of training
Training aim
Area of training 7: Realisation of mechatronic subsystems
To understand the design and mode of operation of a PLC. To design and document control systems for simple applications. To program simple control processes via PLC: Logic operations, memory functions, timers, counters. To carry out programming in one of the PLC programming languages – ladder diagram, function chart or statement list – in accordance with DIN EN 61131-3. To document control systems in function diagrams and function chart according to DIN EN 60848.
Area of training 8: Design and creation of mechatronic systems
To program mechatronic systems in one of the programming languages – ladder diagram, function chart, statement list, sequential function chart. To program the mode section. To program a sequence control.
Area of training 9: Analysing the information flow in complex mechatronic systems
To use computer-aided diagnostic methods, e.g. testing and diagnostic functions of the programming system.
Area of training 11: Commissioning, fault finding and corrective procedures
To eliminate errors in the PLC program.
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Training content: Systematic fault finding on systems
Mechatronics engineers Area of training
Training aim
Area of training 4: Analysing the energy and information flow in electrical and hydraulic modules
Fault finding on simple modules with the help of measurement technology.
Area of training 7: Realisation of mechatronic subsystems
To check control systems for simple applications, e.g. by means of signal analysis.
Area of training 8: Design and creation of mechatronic systems
To identify errors by means of signal analyses at interfaces and eleminating error causes.
Area of training 9: Analysing the information flow within complex mechatronic systems
To analyse signals (binary, analogue, digital) and deduce potential error sources.
Area of training 11: Commissioning, fault finding and corrective procedures
To understand the procedure for fault finding in electrical, pneumatic and hydraulic systems.
Computer simulation
To use computer-aided diagnostic methods, e.g. the testing and diagnostic function of the programming system.
To carry out a fault analysis. To have a command of and apply systematic fault finding. To recognise typical error causes. To make specific use of diagnostic systems. To document faults. To create a log of corrective procedures.
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6.5 The training concept of COSIMIR® PLC
COSIMIR® PLC is a motivating, multimedia training aid on the subject of automated systems. The systems vary in complexity and can be flexibly programmed. Problem definitions can thus be formulated according to requirements and the instructor’s previous knowledge. It is therefore for instance possible to analyse the mode of operation of individual components. Similarly, it is possible to program and test the mode section of a system. Simulated processes have an innate didactic quality: • They are practice-related and as representational as possible. • The ability to experiment with process models creates an environment close to that of an actual system, which is the real object of training and knowledge is tested and consolidated. • Practice-related experience with simulated processes lends a new dimension and quality to knowledge in that theoretical knowledge becomes application and practice-orientated competence. COSIMIR® PLC supports self-motivated, experimental learning: • A simulated system operates in the same way as an actual system. This enables students, for instance, to immediately see whether they have programmed the sequence of a system correctly. The effect of incorrect operation also is apparent without causing any damage to the system. This enables students to independently reach and analyse their findings. • Students can access technical documentation about process models according to their needs. • Students can practice their knowledge and skills on a wide range of different process models.
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What are the advantages of COSIMIR® PLC as a training medium? • COSIMIR® PLC is a PC-assisted training aid and therefore represents an alternative training method. Training can be devised in a diversified and motivating way. • Industry-based process models are used to practice and consolidate the knowledge and skills acquired on actual systems. • Simulated processes can be used to highlight and experiment with statuses, which would be too hazardous on actual systems. • Efficient, practice-related hands-on training is possible without the use of an actual system. • A one-off, actual system is available in the form of several simulated systems, which increases the availability of this system for training purposes. • The actual and virtual world of automation can be combined in any way and adapted to the requirements of the learning process. • All systems simulated in COSIMIR® PLC are also available in the form of actual systems and can be ideally combined and supplemented for training. • Skills and activities which can only be acquired and practiced on actual systems should not to be replaced, but supplemented, practised and consolidated. • Simulation is an advanced tool for use with automated systems. Example 1 To ensure that the PLC programs and design of a system are ready at the same time, appropriate simulation of the system is used to test the PLC program. Example 2: Since production systems should have as few downtimes as possible, simulated systems are often used to train and familiarise operators and maintenance personnel with systems.
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7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
COSIMIR® PLC supports you in many different ways with the familiarisation and analysis of a system. The systematic procedure you use to do so and the knowledge you acquire can be transferred to any system and of course also an actual system. Load a process model to COSIMIR® PLC . Whilst the process model is being simulated, you can control, monitor and analyse the process, which follows the specification of the PLC program provided. The supplied PLC program defines a possible sequence and operation of the process. The process model can however also be controlled via a different PLC program.
Prerequisite
• •
The selected process model is operational and there are no faults in the process. The selected process model is to be controlled via the internal PLC. A correct STEP 7 PLC program is available in the form of a sample program. The sample program is loaded to the internal PLC.
7.1 Training aims
These training aims can be taught with the use of COSIMIR® PLC :
Main training aim
•
To analyse and understand automated systems on the basis of technical documentation and with the help of simulated processes.
General training aims
•
To identify the function and mode of operation of the individual components. To break down the system into function blocks in order to identify the system structure. To identify and track the signal , material and energy flow of the system.
• •
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•
• • • •
•
7.2 Methods
To identify the controller behaviour and the operating sequence of the system with the help of the technical documentation, i.e. Function Chart. To familiarise students with the operation of the system. To understand the product and the processing method. To investigate the system with the help of the simulated process. To use the technical documentation specifically to investigate the system. The technical documentation is comprised of the following: Function chart, circuit diagrams, operating instructions, commissioning instructions, data sheets. To identify the advantages of a simulated process for the operating sequence.
To be able to understand and analyse a system, you will need to subdivide. One possible way, is to subdivide a system into the areas of system and controller structure, mechanical configuration, drive technology, control elements, control system, signal generators and energy supply.
No.
Function scope
Components and component parts
1
System structure and controller structure
Program flow charts, function charts, function diagrams, description
2
Mechanical configuration
Support and mounting unit, function units, adjustment
3
Drive technology
Electrics, hydraulics, pneumatics, mechanics
4
Control elements
Electrics, hydraulics, pneumatics, mechanics
5
Control system
Electrical relay controller, PLC, pneumatics, CNC, robot controllers
6
Signal generators
Binary sensors, analogue sensors, digital sensors
7
Energy supply
Electrics, hydraulics, pneumatics
Structure of a system
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This structure serves as the basis for a systematic procedure to analyse and investigate the system. Questions regarding the individual function scopes provide ideas and guidance as to what exactly you should investigate within the individual function scopes.
Questions
Documents
Function scope - system and controller structure – What is the function of the system? – What is the system to produce? – How is the operating sequence of the system defined? – What control functions are provided? – What display functions are provided? – What type of control system is available: Logic control system, sequence control? – What function units does the system consist of? – Are the function units or components networked? – What bus systems are used: PROFIBUS, AS-i, Ethernet, or similar? – What information is exchanged within the system? – What information is exchanged with other systems or higher order processes? – What does the material flow look like? – What does the signal flow look like?· – What does the energy flow look like? – What does the information flow look like? – What are the possibilities of tracing the signal flow? – – – – – –
Program flow chart Function chart Function diagrams Description Operating instructions Commissioning instructions
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Questions
Documents
Questions
Documents
Questions
Documents
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Function scope - drive technology – What drives are incorporated: Linear drive, swivel drive, rotary drive, electric motor – Which drive technology is used: Electrical, pneumatic, hydraulic? – –
Circuit diagrams Data sheets
Function scope - control elements – What control elements are incorporated? – How are the control elements actuated: Electrically, pneumatically, hydraulically? – How high is the control voltage used for electrically actuated control elements? – What interfaces occur between the signal control section and the power section? – How do the control elements react in the event of Emergency-Stop? – What are the status display options of control elements? – –
Circuit diagrams· Data sheets
Function scope - the control sysem – How is the control system realised: PLC, relay control, robot control, CNC, pneumatic control? – Which control energy does the PLC require? – What is the voltage applied at the PLC inputs? – What is the voltage applied to the PLC outputs? – Is a bus system used? – Which fieldbus system forms part of the control system? – –
Circuit diagrams Data sheets
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Questions
Documents
Questions
Documents
Function scope - signal generators – Which signal generators are incorporated: Binary, analogue, digital? – Which electronic signal generators are incorporated: Optical sensors, inductive sensors, capacitive sensors, magnetic sensors? – What is the design (polarity of the output signal) of the electronic sensors: PNP, NPN? – Which mechanically actuated sensors are incorporated? – Which pressure sensors are incorporated? – What are the status display options of the sensors? – –
Circuit diagrams Data sheets
Function scope - energy supply – Which energy supply is used? – How high is the operating pressure in the case of pneumatic or hydraulic energy supply? – Is direct or alternating current used? – How high is the operating voltage: 24 V or 230 V? – –
Circuit diagrams Data sheets
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7.3 Support via COSIMIR® PLC
COSIMIR® PLC supports you with the following during your analysis and investigation of the system: • Simulation of the process model and execution of the PLC program in the internal PLC. • Window for PLC inputs/outputs: Display of the PLC inputs/outputs. • Window for manual operation: To monitor process activities and process statuses. • Window for manual operation: To set breakpoints to enable you to monitor system operation step by step. • Window for manual operation: To set specific breakpoints in order to stop the process at a particular step. • COSIMIR® PLC Assistant: Provides information on-line, such as circuit diagrams for the process model.
7.4 Example
Investigating the operating sequence of the Distribution station
Exercise
Investigate the operating sequence of the distribution station. To do so, use the checklist containing the system structure. Answer the following questions: • How is the initial position of the system defined? • What is the purpose of the Reset function? • What is defined as the start precondition: Does it include the execution of the Reset function? • How does the distribution station react if no more workpieces are available? • No more workpieces are available in the stacking magazine. What do you need to do for the station to operate correctly again?
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Implementation
1. Load the Distribution process model controlled via the internal PLC.
2. The system can be broken down into the following function blocks: Stacking magazine, swivel drive and electrical. The electrics also include the PLC.
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3. Refer to the technical documentation for information regarding the initial position and start condition of the system. To do so, access the on-line help for the process model. Click onto Help with the Work Cell in the Help menu. The required information is available in the chapters „The Distribution Station“ and „Technical Documentation“.
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Result
Initial position: Ejecting cylinder extended (1B2=1) and swivel arm at magazine (3S1=1) and workpiece not picked up (2B1=0). The system moves to the initial position via the Reset function. The start condition is met if the station is reset and in the initial position.
4. Start the simulation of the process model by clicking onto Start in the Execute menu. 5. Control the process by means of the pushbuttons and switches of the control console. Carry out the reset function first by clicking onto the green illuminated Reset button. Then place two workpieces into the magazine by clicking onto the workpieces on the slotted assembly board. Start executing the process by clicking onto the Start button. You can now follow the implementation of the process.
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6. If there are no further workpieces in the magazine, the swivel arm stops in the adjacent station position. The indicator light Q1 is illuminated. The designation of the indicator light in the circuit diagram is H3.
7. Fill the magazine with workpieces. Click onto the illuminated Start button to acknowledge that you have finished filling the magazine.
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8. Open the Manual Operation window, if you want to execute a process sequence step by step, to enable you to monitor it more effectively. To do so, click onto Manual Operation in the Execute menu. Highlight all the process activities and set breakpoints at these process activities by activating the context sensitive menu via the right mouse button. Select Stop at Value Change. Start the simulation of the process model. Simulation stops at each value change. As soon as simulation is re-started, the next step is executed.
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9. You can trace the signals in the process via the status display in the Manual Operation window or via the LEDs of the process components. 10. To access information regarding the circuit diagram designations of process components, click onto the LED or the air connection of a component.
Note
If, as a result of simulation, the process model reaches a status you cannot or do not want to work with any longer, return the process model to the initial position by stopping the simulation. Then click onto Work Cell Initial Position in the Processing menu.
7.5 Example
Determining the components of the Distribution station
Exercise
Investigate the design of the Distribution station. Use the checklist detailing the structure of the station and the questions regarding the system for this. Answer the following questions: • With which valve is the swivel drive actuated? • How is the vacuum generated? • What are the designations of the solenoid coils of the valve for the ejection of the workpieces? • Via which sensor is the filling level of the magazine monitored? • How many PLC inputs and PLC outputs are required for the control of the Distribution station?
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Implementation
1. Load the Distribution process model controlled via the internal PLC.
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2. Refer to the technical documentation for information regarding the process components and their circuit diagram designations. To do so, open the on-line help for the process model and click onto Help with the Work Cell in the Help menu. The required information is available in the chapter „Technical Documentation“.
Result
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The swivel drive is actuated via two 3/2-way solenoid valves. This valve combination has the function of a 5/3-way solenoid valve with midposition pressurised. The circuit diagram designation for this valve is 3V1. The vacuum is generated via a 2/2-way solenoid valve. The second 2/2-way solenoid valve creates an ejector pulse, which results in reliable ejection once the vacuum is switched off. The circuit diagram designation for the valve is 2V1. All valves are housed on one valve terminal. The designation of the valve coil of valve 1V1 for the actuation of the ejecting cylinder is 1Y1. The filling level of the magazine is checked via the optical sensor with the circuit diagram designation B4.
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3. Take a look also at the process components in the process model itself. Click onto the LED or the air connection in order to display the designation. To enlarge or turn the components, use the options in the View menu. You can restore the standard setting of the process model by clicking onto Standard in the View menu and then selecting Presetting.
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4. Determine the number of PLC inputs and outputs required to control the process. You will find the relevant information for this in the technical documentation via the on-line help. You can however also display the PLC inputs/outputs and their statuses in a separate window for the process model by clicking onto Inputs/Outputs under Extras and selecting Display Inputs and Display Outputs.
Result
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The process control system requires 12 PLC inputs and 8 PLC outputs.
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7.6 Example
Tracing the signal and energy flow on the Distribution process model
Exercise
Investigate the signal and energy flow of the Distribution station. To do so, trace the signal of the sensor 1B1 up to the respective PLC input. Trace the signal and energy flow from the PLC output 3Y1 to the pneumatic drive. Answer the following additional questions: • To which PLC input is the sensor 2S2 connected? • To which PLC input is the sensor B4 connected? • Which drive is actuated via the solenoid coil 1Y1? • To which PLC output is the vacuum generator connected?
Implementation
1. Load the Distribution process model controlled via the internal PLC.
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2. Refer to the technical documentation for information regarding the signal and energy flow of the sensor 1B1 and the PLC output 3Y1. To do so, open the on-line help for the process model and click onto Help with the Work Cell in the Help menu. The required information is available in the chapter „Technical Documentation“.
Result
The sensor 1B1 is connected to the PLC input 1B1 (I0.2). The PLC output 3Y1 (O 0.3) controls the valve coil 3Y1 of the valve 3V1.
3. Move the process model into the initial position by clicking onto Work Cell Initial Position in the Processing menu. 4. Start the simulation by clicking onto Start in the Execute menu. 5. Establish where the components are located in the system and investigate the signals and energy flow of these. You will recognise the components by their circuit diagram designation. 6. Control the process by using the pushbuttons and switches of the control console. First, carry out the reset function by clicking onto the green illuminated Reset button. Then fill the magazine with workpieces by clicking onto one of the workpieces on the slotted assembly board. Start the process operation by clicking onto the Start button. You can now follow the process execution.
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7. Carry out the process activity step-by-step to enable you to better monitor everything. Open the Manual Operation window by clicking onto Manual Operation in the Execute menu. Highlight all the process activities and set the breakpoints at these by activating the context sensitive menu via the right mouse button. Select Stop at Value Change. Start the simulation of the process model. Simulation stops with each value change. The next step in the process is executed as soon as you restart simulation.
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8. Monitor the signal flow of the sensor 1B1. The sensor 1B1 is connected to the PLC input 1B1, i.e. to STATION_1B1. The sensor status can be established via the LED on the sensor. You can also monitor the switching status of the sensor in the Manual Operation window. If the sensor 1B1 switches, then a 1-signal is applied at the PLC input STATION_1B1. The status of the PLC inputs is displayed in the Inputs window. Open this window by clicking onto PLC Inputs/Outputs in the Extras menu and select Display Inputs.
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9. Monitor the signal and energy flow of the PLC output STATION_3Y1. The PLC output STATION_3Y1 is connected to the valve coil 3Y1. The status of the PLC can be established in the Ouputs window. Open this window by clicking onto PLC Inputs/Outputs in the Extras menu and select Display Outputs. If a 1-signal is applied at the PLC input, voltage is also applied at the valve coil 3Y1. The LED of the valve coil is illuminated. If a 0-signal is also applied simultaneously at the valve coil 3Y2, then the valve 3V1 switches. The swivel arm moves into the magazine position.
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When investigating a system, the main focus can be put on familiarisation with the components, in which case the system will not be not controlled via a PLC program. To enable you to more closely observe the mode of operation and behaviour of a component, COSIMIR® PLC allows you to operate individual actuators “by hand”, similar to an actual station. With manual operation, an electrical signal is generated at the selected solenoid coil and the valve switches according to the signal applied and controls the drive. The system components can be specifically controlled via manual operation. You can trace the signal and energy flow, identify interfaces and therefore systematically analyse and understand the system.
Prerequisite
• •
The process model selected is operational and there are no faults within the process. The process model selected will not be controlled via a PLC. The working energies current and compressed air are connected.
8.1 Training aims
The following training aims can be taught with the use of COSIMIR® PLC:
Main training aim
•
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Familiarisation with the individual components of an automated system: Mode of operation, status display elements, mechanical characteristics.
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General training aims
• • • • • • • •
Familiarisation with the mode of operation of sensors and limit switches. To be able to identify application areas for optical, magnetic, inductive and capacitive sensors. To be familiar with the DC motor as an example of an electrical drive. To know of examples for pneumatic linear drives and rotary drives. To be familiar with the design and mode of operation of electropneumatic valves. To analyse and understand the signal and energy flow of components. To be familiar with electropneumatic circuits. To be familiar with status display components on electrical components and to use these for signal tracing.
8.2 Methods
Use a systematic approach to familiarise yourself with a system or system components. The instructions for a systematic procedure are set out in Chapter 7.
8.3 Support via COSIMIR® PLC
COSIMIR® PLC supports you with the following during your analysis and investigation of the components which formpart of a system: • Simulation of the process model. The PLC programs are not active during this. • Window for manual operation: Monitoring of process activities and statuses. • Window for manual operation: Initiating individual process activities. • COSIMIR® PLC Assistant: Provides information on-line, such as circuit diagrams for the process model.
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8.4 Example
Investigating the mode of operation of the ejecting cylinder in the stacking magazine module
Exercise
Investigate the mode of operation of the stacking magazine. Answer the following questions: • How is the initial position of the stacking magazine defined? • What is the status of the ejecting cylinder in the initial position? • How do you identify whether the ejecting cylinder is extended or retracted? • Via which valve is the ejecting cylinder actuated? • What is the designation of the valve solenoid coil for the actuation of the ejecting cylinder? • How can you identify whether voltage is applied at the solenoid coil? • Is the sensor for workpiece detection an inductive, capacitive or optical sensor? • Which signal is applied at the sensor if a workpiece is available in the magazine?
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Implementation
1. Load the stacking magazine process model. Since neither a sample PLC program is available for the stacking magazine nor a PLC program is to be executed, you can load the work cell for the internal or external PLC.
Note
Proceed as follows, when carrying the investigation of individual components on a process model for which a sample program is available: • Load the process model controlled via the internal PLC. • Open the Manual Operation window. • Activate the context-sensitive menu via the right mouse button. Select Disconnect Controllers. • Carry out your investigations by means of manual operation. • Once you have completed your investigations and want to control the process model via the internal PLC, connect the simulation of the process model with the internal PLC. To do so, activate the contextsensitive menu via the right mouse button and select Restore I/O Connections.
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2. Establish which components the stacking magazine consists of. You can find the relevant information by clicking onto the LED or the compressed air connection of the component. Additional information is available in the technical documentation. This technical documentation is available on-line. To access this, open the on-line help for the process model by clicking onto Help with the Work Cell in the Help menu. You will find the required information in the chapter „Technical Documentation“.
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Result
The ejecting cylinder separates out the workpieces. The end positions of the ejecting cylinder are detected via two sensors: Sensor 1B1 (ejecting cylinder retracted), sensor 1B2 (ejecting cylinder extended). The valve for the actuation of the ejecting cylinder is a 5/2-way solenoid valve with the designation 1V1. The valve coil 1Y1 actuates the valve 1V1. The optical sensor B4 detects whether a workpiece is available in the magazine.
3. Make sure that the stacking magazine is in the initial position by clicking onto Work Cell Initial Position in the Processing menu. In the initial position, the ejecting cylinder is extended. 4. Start the process model simulation by clicking onto Start in the Execute menu.
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5. Open the Manual Operation window by clicking onto Manual Operation in the Execute menu.
6. Add a workpiece into the magazine by clicking onto one of the workpieces on the slotted assembly board. Check whether the status of the sensor B4 changes. You can identify the switching status of the sensor on the LED of the sensor. You can however also establish the sensor status via the Manual Operation window.
Result
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No workpiece available: Workpiece available:
B4=1 B4=0.
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7. Eject a workpiece from the magazine by applying a 1-signal at valve coil 1Y1. Double click onto line 1 of the process activities. Valve coil 1Y1 is set at value 1 and the ejecting cylinder ejects a workpiece. No compressed air tubing is shown in the simulation. Applied compressed air is signalled by means of a blue connection.
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8. Return the magazine ejector to the magazine by double clicking onto line1 of the process activities. This double click changes the value of the valve coil from 1 to 0; the ejecting cylinder extends again. 9. Remove the ejected workpiece by double clicking onto line 2 of the process activities. The workpiece is removed.
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COSIMIR® PLC offers you numerous process models for automated applications that are typical in industry. You determine the process sequence, which can be either simple or complex. You then create the PLC program for this sequence in the programming system and for the PLC of your choice. The PLC program is subsequently used to control the process model. You can immediately detect whether the PLC program is operating correctly. If errors occur, then use the testing and diagnostic functions of your programming system for error detection and error elimination. The main focus of COSIMIR® PLC as part of PLC programming is on: • Practising a systematic procedure to create the PLC program. • Systematic testing of the PLC program on the simulated process. The advantage is that relevant actual systems exist for these process models. This enables you to carry out comprehensive commissioning on the actual systems with the tested PLC programs.
Prerequisite
• •
The selected process model is operational and there are no faults within the process. The process model selected is to be controlled via an external PLC.
9.1 Training aims
COSIMIR® PLC is a tool for the process of creating a PLC program. With the help of this tool you can teach the following training contents.
Main training aim for the Beginners target group Beginners
•
To design, create and test PLC programs for simple motion sequences.
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General training aims for the target group Beginners
• • • •
• •
To describe the design and function of a PLC. To list the differences between a PLC and relay control. To realise simple control tasks using basic logic functions (and timers). To program simple control tasks in one of the programming languages: Ladder diagram, function chart or statement list according to DIN EN 61131-3. To test PLC programs for simple control tasks. To systematically solve simple control problems from problem definition and analysis through to finding a solution, programming, checking and documentation.
Main training aim for the Advanced target group
•
To design, create and test a PLC program for extensive control systems.
General training aim for the Advanced target group
•
To program sequence control systems in sequential function chart according to DIN EN 61131-3. To program the mode section. To utilise the diagnostic and testing functions of the PLC programming system. To systematically solve control tasks from problem definition and analaysis through to finding a solution, programming, checking and documentation.
• • •
9.2 Methods
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PLC programs – or more generally control programs - are an important component part of an automated system. In order for PLC programs to be as error-free, easy to maintain and cost effective as possible, they need to be systematically designed, well structured and documented in detail.
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Proceeding in stages has proved a successful method for the development of a PLC program. Breaking down the process into stages or sections provides a targeted, systematic approach and gives clearly configured results that can be checked against the problem definition.
Stages
Activities
Result/documents
Specification (description of the control task)
– Description of the system – Defining the system process
– Function description – Positional sketch – Technology layout
Planning and design (description of the solution)
– Planning the system – Defining the control technology requirements (Emergency-Stop, modes of operation, visualisation...) – Design of the PLC program (formal representation of the sequence and logic of the PLC program)
– Circuit diagrams· – Parts lists· – Solution in the form of a function table or logic diagram to IEC 617-12 for sequence controllers – Solution in the form of a function chart to DIN EN 60848 for sequence controllers – Function diagrams – Definition of software modules
Realisation (Implementation of the solution)
– Programming of the PLC progam – Simulation and testing of program sections and the overall program – Construction of the system
– Annotated PLC program in one of the programming languages to DIN EN 61131-3
Commissioning (integration and testing of the solution)
– Testing and commissioning of the control system
– Operational PLC program – Commissioning report – Storage medium with PLC program – Full documentation
Stages within the systematic solution of a control task
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9.3 Support via COSIMIR® PLC
COSIMIR® PLC with the following for PLC programming: • Industry-typical, realistic process models of varying complexity. • Simulation of the process model. • Control of the process model via OPC interface using any PLC (for example via S7-PLCSIM). • Window for PLC inputs/outputs: Display of PLC inputs/outputs. • Window for manual operation: Monitoring process activities and process statuses. • COSIMIR® PLC Assistant: Provides information such as system description or circuit diagrams.
9.4 Example
Programming the display of the initial position of the Distribution process model.
Exercise
On the Distribution station, the indicator light H1 is to be illuminated if the station is in the initial position.
Ancillary conditions
Your task
The technical documentation for the station is to be used, such as the circuit diagrams and symbols table. You will find these in COSIMIR® PLC Assistant.
• • •
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Represent the control function in the form of a logic diagram. Program the control task in one of the following languages: Ladder diagram, function chart or statement list. Test the PLC program using the simulated process model.
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Implementation using the programming system STEP 7and the Soft PLC S7-PLCSIM 1. Start COSIMIR® PLC . 2. Load the Distribution process model controlled via the external PLC.
3. Use the technical documentation to find out how the initial position of the station is defined. To do so, open the on-line help for the process model and click onto Help with the Work Cell in the Help menu. You will find the required information in the chapters „The Distribution Station“ and „Technical Documentation“.
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Result
Initial position: Ejecting cylinder extended (1B2=1) and swivel arm at magazine (3S1=1) workpiece not picked up (2B1=0). 4. Formulate the control function in the form of a logic diagram.
Result
1B1 3S1 2B1
&
H1
Logic diagram
5. Create the symbols table for the control function. Take the required inputs/outputs from the general symbols table for the Distribution station. The symbols table is available via the online Help for the work cell. Activate the on-line Help by clicking onto Help with the Work Cell in the Help menu
Result
Symbol
Address
Data type
Comment
1B2
I 0.1
BOOL
Ejecting cylinder extended
2B1
I 0.3
BOOL
Workpiece picked up
3S1
I 0.4
BOOL
Swivel arm in magazine position
H1
O 1.0
BOOL
Indicator light Initial position
6. Start STEP 7 or the SIMATIC Manager. 7. Plan a project for the control function.
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8. Create the PLC program and store this.
9. Open S7-PLCSIM by clicking onto Simulate Module under Options in the SIMATIC Manager. 10. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto the MRES button in the CPU 300/400 window.
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11. Load the PLC program to the S7-PLCSIM. In order to do this, highlight the folder Module, then click onto Load in the Target System menu. 12. Start the S7-PLCSIM by clicking onto the box next to RUN in the CPU 300/400 window. 13. Start the process model simulation by activating Start in the Execute menu.
Note
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With the starting of the process model simulation, the communication program EzOPC is also started. If EzOPC is started, both communication users - S7-PLCSIM and process model simulation must already be active. Only then can the communication link be correctly set up.
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14. Carry out the settings in EzOPC. Click onto the EzOPC button in the Start bar. This will open the EzOPC window. Click onto Communication Setup in the Configuration menu. Carry out the necessary settings. In the Easy Port section, select Not Connected for EasyPort 1. In the PLCSIM section, select Installed for STEP 7 PLCSIM V5.x. Accept the preset values 0 and 32 for Start Byte and End Byte without changing it, although only the first four bytes are required. In the section VirtualPLC, select PLCSIM for Connect VirtualPLC to:. Click onto OK to confirm your settings.
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15. These changes may require EzOPC to be restarted. Close the EzOPC program and carry out the restart from the start menu. EzOPC can be accessed via the default setting Programs -> Festo Didactic -> EzOPC V4.9.2 . 16. Minimise the EzOPC window. 17. If your PLC program is correct, the indicator light H1 is illuminated if the station is in the initial position. 18. If PLC program still contains errors, then the on-line view in STEP 7 will support you ideally during fault finding. Call up the program module , in which you suspect the fault and activate Monitor in the Test menu. You can now monitor in parallel with simulation, which PLC program sections are or are not being executed.
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9.5 Example
Programming a simple sequence for the Distribution station
Exercise
A simple sequence is to be programmed for the Distribution station. The sequence is defined as follows: 1. The swivel drive swivels to the „Succeeding Station“ position, if workpieces are detected in the magazine and the Start button is pressed. 2. The ejecting cylinder retracts and ejects a workpiece from the magazine. 3. The swivel drive moves to the „Magazine“ position. 4. The vacuum is switched on. If the workpiece is reliably picked up, a vacuum switch switches. 5. The ejecting cylinder extends and releases a workpiece. 6. The swivel drive moves to the „Succeeding Station“ position. 7. The vacuum is switched off. 8. The swivel arm moves to the „Magazine“ position.
Ancillary conditions
The technical documentation for the station is to be used, such as circuit diagrams and the symbols table. You will find these in COSIMIR® PLC Assistant.
Your task
• • •
Represent the control task in function chart according to DIN EN 60848. Program the control task in sequential function chart. Test the PLC program with the simulated process model.
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Implementation using the programming system STEP 7 and the Soft PLC S7-PLCSIM 1. Start COSIMIR® PLC . 2. Load the Distribution process model, controlled via the external PLC.
3. Refer to the technical documentation to find out which process components are used and what the designations of the components are in the circuit diagram. Open the on-line help to do so and activate Help with the Work Cell in the Help menu. You will find the required information in the chapter „Technical Documentation“. 4. Formulate the control task in function chart.
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Result
Function chart to DIN EN 60848 (IEC 60848)
1 Start
Station in initial position and part in magazine and Start button 2 Swivel arm to “Succeeding Station” pos.
Swivel arm to “Succeeding Station” position
Swivel arm in “Succeeding Station” position 3
Eject workpiece
Magazine slide forward (ejecting cylinder to retract)
Workpiece ejected 4
Swivel arm to “Magazine” position
Swivel arm to “Magazine” position
Swivel arm in “Magazine” position 5
Pick up workpiece
Vacuum ON Magazine slide back (ejecting cylinder to extend)
Workpiece picked up and magazine slide back 6 Swivel arm to “Succeeding Station” pos.
Swivel arm to “Succeeding Station” position
Swivel arm in “Succeeding Station” position 7
Deposit workpiece
Vacuum OFF
Workpiece not picked up 8
Swivel arm to “Magazine” position
Swivel arm to “Magazine” position
Swivel arm in “Magazine” position
Function chart for the control task
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5. Create the symbols table for the control task. Take the required inputs/outputs from the general symbols table for the Distribution station. You will find the symbols table on the on-line help for the work cell.
Result
Symbol
Address
Data type
Comment
1B2
I 0.1
BOOL
Ejecting cylinder extended
1B1
I 0.2
BOOL
Ejecting cylinder retracted
2B1
I 0.3
BOOL
Workpiece picked up
3S1
I 0.4
BOOL
Swivel drive in magazine position
3S2
I 0.5
BOOL
Swivel drive in succeeding station position
B4
I 0.6
BOOL
Magazine empty
S1
I 1.0
BOOL
Start button
1Y1
O 0.0
BOOL
Ejecting cylinder to retract (magazine slide advanced)
2Y1
O 0.1
BOOL
Switch on vacuum
2Y2
O 0.2
BOOL
Switch off vacuum
3Y1
O 0.3
BOOL
Swivel cylinder to magazine position
3Y2
O 0.4
BOOL
Swivel cylinder to succeeding station position
6. Start STEP 7, i.e. the SIMATIC Manager respectively.
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7. Create a project for the control task. 8. Create the PLC program and store it.
9. Open S7-PLCSIM by clicking onto Simulate Modules under Options in the SIMATIC MANAGER. 10. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto the MRES button in the CPU 300/400 window.
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11. Load the PLC program to S7-PLCSIM. To do so, mark the Modules folder and then activate Load in the Target System menu. 12. Start S7-PLCSIM by clicking onto the box next to RUN in the CPU 300/400 window. 13. Start the simulation of the process model by clicking onto Start in the Execute menu.
Note
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With the starting of the process model simulation, the communication program EzOPC is also started. If EzOPC is started, both communication users - S7-PLCSIM and the simulation of the process model – must already be active. Only then will the communication links be correctly set up.
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14. Carry out the settings in EzOPC. Click onto the EzOPC button in the Start bar to open the EzOPC window. Click onto Communication Setup in the Configuration menu. Carry out the necessary settings. In the EasyPort section, select Not connected for EasyPort 1. Select Installed in the section PLCSIM for STEP 7 PLCSIM V5.x. Accept the preset values 0 and 32 for Start Byte and End Byte without changing them, although only the first four bytes are required. Select PLCSIM for Connect VirtualPLC to: in the section VirtualPLC. Click onto OK to confirm your settings.
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15. The changes may require EzOPC to be restarted. Close the EzOPC program and carry out the restart via the start menu. EzOPC can be accessed via the default setting -> Festo Didactic -> EzOPC V4.9.2. 16. Minimise the EzOPC window. 17. If your program is correct, you can start the sequence once you have inserted a workpiece by clicking onto the Start button. 18. If the PLC program still contains errors, the on-line view in STEP 7 will support you ideally with fault finding. Call up the program module, where you suspect an error. Activate the command Monitor the Test menu. You can now monitor, in parallel with the process simulation, which PLC programs are or are not being executed.
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COSIMIR® PLC supports you in numerous ways during systematic fault finding on a simulated system. The systematic procedure, the working aids and diagnostic systems used for this and the know-how you acquire, can be applied to any system. Load a process model in COSIMIR® PLC . A fault has been previously set on this process model. You can now control and monitor the process model as it is being simulated. Analyse the fault behaviour and determine the cause of the fault. When you have found the cause, eliminate the fault by entering the cause of the fault in the window provided. If you have identified the cause of the fault, then the process model will operate correctly during the next simulation run.
Prerequisite
• • •
The selected process model is loaded and a fault set in the process model by an authorised person. The fault simultation mode is active. The selected process model is controlled via the internal PLC. A correct PLC program is available and the sample program is automatically loaded to the internal PLC.
10.1 Training aims
You can impart these training aims with the use of COSIMIR® PLC :
Main training aim
•
Systematically repairing a system after a fault has occurred.
General training aims
•
To familiarise students with and apply a general procedure for systematic repair work in the event of a fault. To acquire information regarding the mode of operation of a system and system components from technical documentation.
•
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• • • • • • • •
10.2 Methods
To determine the actual status of a system after a fault has occurred. To carry out systematic fault finding on PLC controlled electropneumatic systems. To become familiarised with and apply a strategy for fault finding on PLC controlled electropneumatic systems. To carry out a fault analysis. To know the typical causes of faults. To document faults. To make targeted use of diagnostic systems. To familiarise students with the working aids for fault finding.
The basic prerequisite for systematic fault finding and corrective procedures is to understand the system. Only if you understand the system, its structure and function can you carry out corrective procedures. Eliminating faults by means of systematic corrective procedures. The following methods have proved successful with systematic fault finding and corrective procedures: • Familiarisation with the system • Systematic repair work after a fault has occurred • Systematic determination of the actual status of the system • Systematic fault finding in general • Systematic fault finding for PLC controlled systems
Method: Familiarisation with the system
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Familiarise yourself with the system by: • Investigating the system. • Analysing the system documentation. • Understanding the product and the processing technology. • Conducting informative discussions with system operators.
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Method: Systematic corrective procedures after a fault has occurred
In the event of an inadvertent interruption of the process, corrective procedures are to be carried out according to the following schematic representation:
REQUIRED status
Fault diagnosis
Fault located
Fault finding
No Comparison
ACTUAL status
Yes
Corrective procedures
Recommissioning
Production system
Systematic corrective procedures
In the event of a fault signal, the actual status of the system is to be established first. Once the actual status has been determined and compared with the required status, the actual fault finding starts. The source of a fault is often found during this comparison if the fault • is visible (e.g. mechanical damage on a signal generator) • is audible (e.g. leakage on a valve) • is detectable by suspicious odours (e.g. scorching of a cable).
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If this is not the case, the fault can be found and eliminated by means of systematic fault finding. Once a fault is found, it is not enough to merely correct it. It is also necessary to establish the cause of the fault. A list of faults is is helpful for this and this should be stored in the system. This list describes all the faults and their causes. With the help of a fault list, it is possible to determine whether damage or faults occur regularly. In this way, it is possible to identify weak areas in the system. Once these are established, it is advisable to technically improve the system.
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Method: Systmatically determining the actual system status
First, the actual system status must be determined in the event of an error message. Several options are available for this:
Establishing the actual status Step 1
Determining the fault behaviour of the system
– No start – Standstill during process step – Faulty process sequence – Work result wrong
Step 2
Establishing the actual status of the system
– Status displays (LED) on the system components: – Current mode of operation – Ready status – Signal status of signal generators – Switching status of control elements – Switching status of PLC input/outputs – Visible damage – Audible damage – Damage detectable by odour/smell – Screen: – Error message, diagnostic message – Status information – Machine status display
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Method: Systematic fault finding in general
The basis for systematic fault finding is again the desired/actual value comparison.
Determining of ACTUAL status Comparison with REQUIRED status
Establishing possible error sources a
– Mechanical faults – Pneumatic faults – Hydraulic faults – Electrical faults
Investigating possible sources of faults by means of testing or measurement protocols
NO (fault not found)
Result
YES (fault found)
Elimination of fault and recommissioning
Overview of systematic fault finding
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Method: Systematic fault finding for PLC controlled systems
Every controller functions on the principle of signal input, signal processing and signal output. Systematic fault finding for PLC controlled systems is based on this structure. A desired/actual value comparison enables you to narrow down the area of the fault within the process sequence. Investigate possible causes of faults by checking the components in the direction of the signal and energy flow, starting from the fault location.
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Structure
Working aids
Possible error sources
Checking the electrical energy supply
Voltage tester
– Voltage supply switched off – Voltage supply to high or too low
Checking of sensor
Voltage tester LED
– Sensor incorrectly adjusted – Sensor mechanically displaced – Sensor faulty
Monitoring of PLC input
LED
– PLC input module faulty – Cable break between sensor and PLC input
Checking of PLC
LED Programming and testing unit
– PLC faulty – No voltage applied
Checking of PLC output
LED
– PLC output module faulty
Checking of control elements
Voltage tester LED Manual override
– Control element mechanically faulty – Control element electrically faulty – Cable break between PLC output and control element
Checking of drive
Visual inspection
– Connections mixed up – Loss of electrical connection
Checking of pneumatic or hydraulic energy supply
Pressure gauge
– Energy supply not switched on – Leakage in network
Fault has occurred in the system Establishing the actual status Comparison of actual status with desired status
Systematic fault finding of PLC controlled systems
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10.3 This is how COSIMIR® PLC supports you
COSIMIR® PLC supports you with the following during the monitoring and analysis of the actual system status: • Simulation of the process model and execution of the PLC program via internal PLC. • Window for PLC inputs/outputs: Display of PLC input/outputs. • Window for manual operation: Display of process activities and process statuses. • Window for fault localisation: Input and elimination the cause of the fault. • COSIMIR® Assistant: Provides information on-line regarding the process model, such as circuit diagram or function chart.
10.4 Example
Finding and eliminating faults in the Distribution station
Exercise
A fault has occurred in the course of the sequence of the Distribution station. Eliminate the fault by means of systematic corrective procedures.
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Implementation
1. Load the Distribution process model with the set fault. The process model is controlled via the internal PLC.
2. Ensure that the Fault Simulation mode is active. 3. Put the process model into the initial position by clicking onto Work Cell Initial Position in the Processing menu. 4. Now start the simulation of the process model. To do so, click onto Start in the Execute menu. 5. Operate the process using the pushbuttons and switches of the control console.
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6. A fault has occurred during execution, which stops the process.
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7. Refer to the technical documentation to establish the correct process execution. Open the on-line help for the process model by clicking onto Help with the Work Cell in the Help menu. You will find the required information in the chapters „The Distribution Station“ and „Technical Documentation“.
8. Determine the actual status of the process and compare it with the required status, thereby narrowing down the area of the fault location within the process.
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Result
The fault is a stoppage during the process sequence. The process step „Move swivel arm to magazine position“ is not executed. Possible causes of the fault are: The swivel cylinder and its valve actuation or possibly also the sensors, which should trigger the movement of the swivel cylinder.
9. We recommend that you check the energy flow, starting from the sensors through to the swivel cylinder. It is of course possible to proceed in reverse and to check the signal and energy flow from the swivel cylinder to the valve via the PLC to the sensor. 10. Find out which sensor signals need to be applied in order for the swivel arm to move to the magazine position. Use the function chart and allocation list from the on-line help for the Distribution work cell.
Result
If the reed switch 1B1 and the end position switch 3S2 are actuated, the swivel arm should move to the magazine position.
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11. Check the switching status of the reed switch 1B1 and the end position switch 3S2. Two options are possible. Evaluate the LED in the process model. The designation of the respective component is displayed as soon as you click onto the LED. Or check the signal status of the sensors in the Manual Operation window by clicking onto Manual Operation in the Execute window.
Result
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The LED of the reed switch 1B1 is illuminated and the sensor therefore switches.
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10. This is how you carry out systematic fault finding on a simulated system
12. Check the PLC input 1B1 connected to the sensor by opening the PLC Inputs window. Click onto Inputs/Outputs in the Extras menu and select Display Inputs. The Inputs window is displayed.
Result
A 0-signal is applied at the PLC input STATION_1B1, even though the sensor 1B1 switches. You therefore suspect that the cause of the fault is a cable break at the PLC input 1B1.
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13. Open the Fault Localisation window to eliminate the fault. Click onto Fault Localisation in the Execute menu to do so. Then double click onto No fault on the line PLC input 1B2. Select Cable Break in the list of options.
Result
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The simulation of the process model is continued correctly. The cause of the fault has been correctly identified and eliminated.
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