Prolog Manual A005

Prolog-factory Manual

Order-NR.: Type:

Manual prolog-factory

Designation

Prolog_Manual_A005.doc

Printed:

August 13

Autor:

Schober

Graphics:

Schober

Layout:

Schober

© Festo Didactic GmbH & Co.KG., D-73770 Denkendorf, 2013 Internet: www.festo.com/didactic e-mail: [email protected] This manual, all text and illustrations included, is protected by copyright. Any utilization outside the limits of the copyright law and other than training purposes are not permissible without our definite approval. This applies in particular to reproductions, operations, translations, micro filming and the storing and processing into electronic systems. Parts of this manual may be copied by the authorized user, exclusively for teaching purposes. Distribution of this documentation, as well as reproduction, use and spread of its contents is prohibited, insofar not permitted explicitly. Offences are liable to compensation. All rights reserved, especially the right to execute registrations concerning patents, designs for use and patterns.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

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Intended use

The User Manual must be to hand at all times. Keep it close to the machine.

This installation was developed and manufactured only for use in basic and further training in the fields of automation and communications. The training company and/or the training staff must ensure that the trainees observe the safety precautions described in the accompanying manuals. Furthermore this manual describes setup and possible uses of the singular stations. It contains all information and data required for commissioning, maintenance and operation. Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any third parties occurring when the installation is used for any purpose apart from training, except Festo Didactic has caused such injury or harm intentionally or by grossly negligence.

The manual is divided into four parts: Part A In addition to technical data, Part A contains an overview of the possible uses of the stations. Part B Part B contains some exercises and the solutions for this exercise (Not available for each station). Part C Part C contains the pneumatic and electrical diagrams for the station and the listing of the control programs (Not available for each station). Part D Part D contains data sheets and technical information about the electrical and electronic modules used.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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List of applicable standards and regulations

The list below provides an overview of the most important standards and regulations relating to mechanical, electrical and safety-engineering design and production.

DIN EN 292 -Machine safety DIN EN 60204 - Electrical equipment of industrial machines DIN VDE 0113 - See DIN EN 60204 DIN 40719 - Circuit documentation VDI 2853 - Technical safety requirements concerning the building, equipping and operation of industrial robots VDI 2853 - Technical safety requirements concerning automated production systems VDI 2411 - Terms and explanations in conveying and handling VDI 2860 - Assembly and robotics - terms VDI 2861 - Assembly and robotics - characteristic quantities DIN 19245 - PROFIBUS Part 1-3

As far as possible, the System is maintenance-free. All bearings are lubricated for life. The installation was designed in such a way as to keep the number of wearing parts to a minimum. This does not include machines that are part of optional expansions (such as industrial robots).

At this point we would like to point out that this manual and the concept of the operating instructions for a Flexible Training System of this type are regularly updated. To ensure that the instructions are ever more user-friendly, you would help us a great deal by passing on your suggestions for improvement. Please let us know of your suggestions, corrections or ideas, either in writing or via telephone: +49(711-3467-0)

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Contents 1

Intended use _______________________________________________________ 3

2

Introduction ______________________________________________________ 11 2.1

General ______________________________________________________ 11

2.2

Customer system ______________________________________________ 12

2.2.1

Triple stack magazine station ________________________________ 13

2.2.2

Testing station with color sensor _____________________________ 14

2.2.3

Processing station _________________________________________ 15

2.2.4

Pick and place station ______________________________________ 16

2.2.5

Fluid muscle station ________________________________________ 17

2.2.6

Storing station ____________________________________________ 18

2.2.7

Separating station _________________________________________ 19

2.2.8

Sorting station ____________________________________________ 20

2.2.9

Commissioning station _____________________________________ 21

2.2.10

Log area__________________________________________________ 22

2.2.11

Robotino 1&2 _____________________________________________ 23

2.3

Didactic structure ______________________________________________ 24

2.4

Duty of the operating authority ___________________________________ 27

2.5

Duty of trainees _______________________________________________ 27

2.6

Warranty and liability ___________________________________________ 28

2.7

Intended use __________________________________________________ 28

2.8

Important notes _______________________________________________ 29

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Contents

3

General safety instructions __________________________________________ 31 3.1

Handling the system____________________________________________ 31

3.1.1

Dangers in handling the machine _____________________________ 31

3.1.2

Safety precautions in standard operation ______________________ 32

3.1.3

Dangers due to electric current _______________________________ 32

3.1.4

Dangers due to pneumatic energy ____________________________ 33

3.1.5

Maintenance – Servicing – Malfunction removal _________________ 33

3.1.6

Organizational measures ____________________________________ 33

3.2

Personnel ____________________________________________________ 34

3.2.1

Notes on personnel ________________________________________ 34

3.2.2

Training operations ________________________________________ 34

3.2.3

Outside training operations _________________________________ 34

3.3

Emergency stop system _________________________________________ 34

3.3.1 4

Commissioning ____________________________________________________ 37 4.1

Transport _____________________________________________________ 37

4.1.1

Unpacking ________________________________________________ 37

4.1.2

Scope of delivery __________________________________________ 37

4.2

Set up _______________________________________________________ 38

4.2.1 4.3

General information ________________________________________ 38

Commissioning ________________________________________________ 41

4.3.1

6

Safety symbols ____________________________________________ 35

Pneumatic commissioning___________________________________ 41

© Festo Didactic GmbH & Co.KG. • prolog-factory

Contents

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4.3.2

Electric commissioning _____________________________________ 41

4.3.3

Connecting communication cables ____________________________ 42

Operation ________________________________________________________ 47 5.1

General operation notes ________________________________________ 47

5.1.1

Behaviour rules ___________________________________________ 47

5.1.2

Operation rules ____________________________________________ 47

5.2

Process description ____________________________________________ 48

5.2.1 5.3

Material flow ______________________________________________ 49

Robotino information and operation ______________________________ 51

5.3.1

General __________________________________________________ 52

5.3.2

Start up __________________________________________________ 54

5.3.3

Switch off the robotino _____________________________________ 55

5.4

Program start _________________________________________________ 56

5.6 Program Upload robotino __________________________________________ 57 5.5

Robotino-Pro-Log ______________________________________________ 65

5.5.1

Explanations ______________________________________________ 67

5.5.2

Sequence to collect one Palette ______________________________ 67

5.5.3

Global Variables ___________________________________________ 69

5.6

Data Exchange Variables ________________________________________ 70

5.7

Log area information and operation _______________________________ 71

5.7.1

General __________________________________________________ 71

5.7.2

Start up log area ___________________________________________ 73

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Contents

5.8

5.8.1

Requirements _____________________________________________ 74

5.8.2

Reset process of MPS-stations _______________________________ 74

5.9

6

Start up MPS stations __________________________________________ 74

Start up commissioning station __________________________________ 75

5.9.1

Requirements _____________________________________________ 75

5.9.2

Reset process robot station _________________________________ 75

5.10

Default mode _________________________________________________ 76

5.11

MES Mode ____________________________________________________ 78

WINCC ___________________________________________________________ 79 6.1

System information ____________________________________________ 79

6.1.1 6.2 7

Use Runtime Application ________________________________________ 80

MES Software _____________________________________________________ 87 7.1.1

Settings ______________________________________________________ 88

7.3

Operation ____________________________________________________ 90

7.4

Create a new order ____________________________________________ 103

7.5

Reference guide to create a new order ________________________ 103

Workaround Error on Storage Station ____________________________ 105

Process description _______________________________________________ 107 8.1

Distributing Station ___________________________________________ 107

8.1.1

8

Software requirements _____________________________________ 87

7.2

7.4.1

8

Start-up WINCC ____________________________________________ 79

Standalone mode of Distributing Station______________________ 107

© Festo Didactic GmbH & Co.KG. • prolog-factory

Contents

8.1.2 8.2

MES mode of Distributing Station ___________________________ 108

Testing Station _______________________________________________ 110

8.2.1

Standalone mode of Testing Station _________________________ 110

8.2.2

MES mode of Testing Station _______________________________ 112

8.3

Processing Station ____________________________________________ 114

8.3.1 8.4

Pick & Place Station ___________________________________________ 116

8.4.1 8.5

Standalone mode of Pick & Place Station _____________________ 116

Fluidic Muscle Press Station ____________________________________ 118

8.5.1 8.6

Standalone mode of Processing Station ______________________ 114

Standalone mode of Fluidic Muscle Press Station ______________ 118

Storing Station _______________________________________________ 120

8.6.1

Standalone mode of Storing Station _________________________ 120

8.6.2

MES mode of Storing Station _______________________________ 124

8.7

Separating Station ____________________________________________ 130

8.7.1

Standalone mode of Separating Station ______________________ 130

8.7.2

MES mode of Separating Station ____________________________ 132

8.8

Sorting Station _______________________________________________ 134

8.8.1 8.9

Standalone mode of Sorting Station _________________________ 134

Robot Station and Robotinos ___________________________________ 136

8.9.1

Standalone mode of Robot Station and Robotinos ______________ 136

8.9.2

MES mode of Robot Station ________________________________ 140

8.9.3

MES mode of Robotino 1 ___________________________________ 146

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Contents

8.9.4 9

Technology ______________________________________________________ 151 9.1

drawings ____________________________________________________ 151

9.2

Modules in use _______________________________________________ 152

9.2.1

Pallet ___________________________________________________ 152

9.2.2

Work pieces _____________________________________________ 153

10

Pneumatic _____________________________________________________ 155

10.1 11

Pneumatic supply _____________________________________________ 155 Electrical system ________________________________________________ 157

11.1

Power supply ________________________________________________ 157

11.2

Controller ___________________________________________________ 158

11.3

Wiring ______________________________________________________ 159

11.3.1

10

MES mode of Robotino 2 ___________________________________ 149

I/O-Components __________________________________________ 159

© Festo Didactic GmbH & Co.KG. • prolog-factory

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2.1

Introduction

General

In the development of the system, various production technologies have been combined into one installation. The aim of the installation is the increase of competence, from a simple setting of examples up to a complete production process, including all features. Additionally, to technical and social competence, the comprehension of the process and the interaction of the respective components appear in clear presentation. This manual describes working with the prolog-factory system. Everything is explained and described for the operation of necessary events. With the help of graphics or pictures a simple communication should be obtain. Complete operating instructions which explain the processes of the system are available for working with the system. Station manuals are also available for the individual stations. Festo Didactic succeeded in using the most updated industrial hard- and software for this model production. The PRO-LOG Factory consists of 3 main areas: The Production Line, where the products are produced The Commissioning Station, where the customer orders are picked The Warehouse Area, where the customer orders (pallets) are buffered until delivery The production line itself consists of 8 MPS Stations. Each Station has its own controller to support a decentralized control structure. The Commissioning Station consists of a 6 axis robot. The customer orders are completed according the order data in this station. After completion, the pallets (orders) are put to the warehouse input slide. The warehouse is served by mobile robots. The mobile robots receive their transport orders from the MES according to the warehouse management data. They move Empty pallets to the commissioning robot Completed orders from the warehouse input slide to the high-bay storage Deliveries from the storage to the warehouse output slides

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Introduction

2.2

Customer system

Overview prolog-factory system

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Position

Description

Position

Description

1

Triple stack magazine station

8

Sorting station

2

Testing station with color sensor

9

Robotino 2

3

Processing station

10

Robotino 1

4

Pick and place station

11

Log area

5

Fluid muscle station

12

Commissioning station

6

Storing station

13

Connecting conveyor 3

7

Separating station

© Festo Didactic GmbH & Co.KG. • prolog-factory

Introduction

2.2.1

Triple stack magazine station

Triple stack magazine station

The triple stack magazine station separates workpieces from 3 magazines. Up to eight workpieces are stored in each of the magazine tubes of the stacking magazines. A double-acting cylinder pushes the workpieces out one at a time directly to the transfer point of the downstream station.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Introduction

2.2.2

Testing station with color sensor

Testing station with color sensor

The Testing station detects the various properties of the work pieces inserted into it. It differentiates work pieces with the aid of an laser distance sensor and a color sensor. A retro-reflective sensor monitors whether the operating space is free before the work piece is measured for height. An analogue sensor measures the height of the work piece. At the same time a color sensor is checking out the color of the work piece. The parts are guided on the conveyor to the neighboring station. Faulty work pieces are rejected via a slide.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Introduction

2.2.3

Processing station

Processing station

In the Processing station, work pieces are tested and processed on a rotary indexing table. This station only uses electrical drives. The rotary indexing table is driven by a DC motor. The table is positioned by a relay circuit, with the position of the table being detected by an inductive sensor. On the rotary indexing table, the work pieces are tested and drilled in two parallel processes. A solenoid probe with an inductive sensor checks that the work pieces are inserted in the correct position. During drilling, the work piece is clamped by a solenoid actuator. Finished work pieces are passed on via the electrical sorting gate.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Introduction

2.2.4

Pick and place station

Pick and place station

The Pick and Place station is equipped with a two-axis Pick and Place module. Work piece housings placed on the conveyor are detected by an optical diffuse sensor. The work piece is transported to the pneumatic separator on the conveyor and detected by a second diffuse sensor. The Pick and Place module picks up a work piece insert from the slide and places it on the work piece housing. The complete work piece (housing and insert) is released by the separator and transported to the end of the conveyor. A light barrier detects the work piece at the end of the conveyor. This station can also be used to perform the following tasks: Rejection of work pieces (housing or basic body) on the slide Alternative feeding of work pieces (housing or basic body) from the slide 16

© Festo Didactic GmbH & Co.KG. • prolog-factory

Introduction

2.2.5

Fluid muscle station

Fluid muscle station

The Fluidic Muscle Press station presses work piece inserts into the housings. The rotary/linear actuator (transfer device) moves the housing with the insert placed on it under the press. The pneumatic muscle performs the pressing operation. The finished work piece is then transported to the transfer position using the rotary/linear actuator. An optical diffuse sensor is attached to the arm of the actuator for sensing the work piece. The pressing pressure is monitored and displayed using the analogue pressure sensor. The press-in speed and depth can be varied both manually – via throttle and pressure regulator – and electronically – via the proportional pressure regulator. © Festo Didactic GmbH & Co.KG. • prolog-factory

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Introduction

2.2.6

Storing station

Storing station The Storing station places work pieces in, and takes work pieces out of storage. The station is equipped with three storage levels, with a level each for six red, six silver and six black work pieces. The work pieces are gripped using a pneumatic gripper. The linear movement is executed using a linear cylinder. The rotary movement is performed by an electrical servo drive with integrated controller. The stroke movement is executed using an electrical linear axis with separate controller. During placement into storage, a work piece inserted in the Holder module is detected using the color sensor. The work piece is placed in the next free compartment in the corresponding storage level based on the color. Upon removal from storage, the work pieces are transported from the shelf compartments to the downstream station. The Storing station can be employed as the first station or the last station in an MPS® combination.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Introduction

2.2.7

Separating station

Separating station The Separating station differentiates work pieces based on their color and material with an inductive and an optical sensor. It separates them into two different material flow directions. In default mode the red workpiece are transported to the end of conveyor, the black and silver are transported to the rear. In MES mode the workpiece is transported to the rear, if it is matching with the order (If not, transported to the end of conveyor). Fibre-optic through beam sensors with optical sensors monitor the material flow on the conveyors. The Separating station can be supplemented with MPS® downstream stations in two directions.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Introduction

2.2.8

Sorting station

Sorting station

The Sorting station sorts work pieces onto three slides. Work pieces placed on the start of the conveyor are detected by a diffuse sensor. Sensors upstream of the stopper detect the work piece features (black, red, metal). Sorting gates actuated by short-stroke cylinders via a deflector allow sorting of work pieces onto the appropriate slides. A retro-reflective sensor monitors the level of the slides.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Introduction

2.2.9

Commissioning station

Commissioning station

The commissioning station commissions work pieces from a conveyor on pallets. Empty pallets are moved from the input slide to the buffer positions on the station. The commissioned pallets are moved to the output slide for further use. The complete handling of pallets and work pieces is done be the robot.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Introduction

2.2.10 Log area

Log area

The log area is a logistic field of 2x2m. The high bay racking is used to buffer up to 6 pallets. There are 3 slides for the output of the pallets. Each of these slides is equipped with a RFID Sensor. A further slide for the input of empty pallets is available. The slides to the commissioning station are to supply the commissioning station with empty pallets and to take the equipped pallets from. 2 robotinos are responsible for the handling of the pallets.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Introduction

2.2.11 Robotino 1&2

Robotino

The 2 robotinos are equipped with a lifting system to lift and lay down the pallets from and to the slides. The task of the first robotino is to move the pallets from the output slide of the commissioning station to the high bay racking and to pick up the emtpy pallets from the input slide of the log area and move them to the input slide of the commissioning station. The task of the second robotino is to move the pallets from the high bay racking to the 3 outputs slides from the log area.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Introduction

2.3

Didactic structure

The installation is structured, to enable methodical learning, i.e. from single use of modules to the complex and complete installation. Perhaps even in combination with further systems. For example, it is possible to pick out a single module to start with the first steps, e.g. the robot. First the mechanical assembly is considered. The robot’s radius of action requires integration into the location of the robot. The following step could be the connection of all cables required for operation and the set-up of the robot. Moving the robot and teaching the required positions are the first real operations with the robot, which introduces the user how to deal with the teach-box. The robot’s programming can be started, as soon as the robot can be moved by the teach-box. Small programs, which can be created by using the CIROS/Cosirop software, are expandable for the complex programs. Orders to further stations and from other controls can be installed in the programs.

Once the learning process of this module has been concluded, these learning steps can be transferred to the next module. As soon as all of the modules have been processed individually, the modules can be interconnected and the programs can be adapted. A complete production process can be simulated. This is an ideal training area for the professional practice of mechatronics, as well as all of the technical ranges (mechanical, electrical and pneumatic processes) are represented in a simple and clearly way, concerning each one of the modules and the complete system.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Introduction

The installation permits to face students to the reality of manufacturing processes by allowing them to apply individual technologies already taught in the preliminary phases of engineering studies. Thus, each technology is considered first separately and then combined together to optimize the manufacturing processes. Training contents covering the following subjects can be taught: Mechanic: Adjusting of a handling system Assembly of singular station Using mechanical interfaces Electronic: Wiring and testing electrical components Reading and designing electrical circuit diagrams Getting familiar with electrical drives Working with electrical interfaces Robotic: Use of industrial robots Fundamentals of robot technology Robot programming Sensoric: Using limit switches and sensors Getting to know different types of sensors (inductive, optical, capacitive, analogue) Pneumatic: Professional tubing of pneumatic components according to circuit diagrams Getting to know and using pneumatic components (different cylinders, valves, grippers) Using vacuum technology

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Introduction

Ident system: Getting familiar with the Identification system Data processing via Ident and PLC PLC: Getting to know the structure and mode of operation of a PLC Programming a PLC in different PLC languages Interfacing a PLC to a Robot Controller and a visualization system Getting to know special function modules for positioning, counting Maintenance and Troubleshooting: Locating and rectifying faults and malfunctions Optimizing automated systems Commissioning: Adjusting mechanical and electrical components Adjusting sensors and limit switches in automated systems Commissioning systems by means of a PLC

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Introduction

2.4

Duty of the operating The operating authority undertakes to ensure that the system is used only by persons who: authority are familiar with the basic regulations regarding operational safety and accident prevention and who have received instructions in the handling of the system. have read and understood the chapter on safety and the cautionary notes in this manual. Safety-conscious working of the persons should be regularly vetted.

2.5

Duty of trainees

Prior to commencing work, all persons assigned to working on the system have a duty to: read the chapter on safety and the cautionary notes in this manual and, observe the basic regulations regarding operational safety and the prevention of accidents.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Introduction

2.6

Warranty and liability

In principle all our „Terms and Conditions of Sale“ apply. These are available to the operating authority upon conclusion of the contract at the latest. Warranty and liability claims for persons or material damage are excluded if these can be traced back to one or several of the following causes:  Use of the system not in accordance with its intended purpose  Incorrect assembly, commissioning, operation and maintenance of the system  Operation of the system using faulty safety equipment or incorrectly fitted or non operational safety or protective devices  Non observance of notes in the manual regarding transport, storage, assembly, commissioning, operation, maintenance and setting up of the system  Unlawful constructional modifications on the system  Inadequate monitoring of components subject to wear  Incorrectly carried out repairs  Catastrophes as a result of foreign bodies and vis major.

Festo Didactic herewith rules out any liability for damage or injury to trainees, the training company and/or other third parties which may occur during the use/operation of the system other than purely in a training situation, unless such damage has been caused intentionally or due to gross negligence by Festo Didactic.

2.7

Intended use

This installation was developed and manufactured only for use in basic and further training in the fields of automation and communications. The training company and/or the training staff must ensure that the trainees observe the safety precautions described in the accompanying manuals. Furthermore this manual describes setup and possible uses of the singular stations. It contains all information and data required for commissioning, maintenance and operation. Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any third parties occurring when the installation is used for any purpose apart from training, except Festo Didactic has caused such injury or harm intentionally or by grossly negligence. The use of the system for its intended purpose also includes: Following all advice in the manual and Carrying out inspection and maintenance work.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Introduction

2.8

Important notes

The basic requirement for safe use and trouble-free operation of the system is to observe the fundamental safety recommendations and regulations. This manual contains important notes concerning the safe operation of the system. The safety recommendations in particular must be observed by anyone working on the system. Furthermore, the rules and regulations for the prevention of accidents applicable to the place of use must be observed.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Introduction

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© Festo Didactic GmbH & Co.KG. • prolog-factory

3

3.1

General safety instructions

Handling the system

3.1.1

Dangers in handling the machine

The installation has been constructed technologically up to date and in conformance with the recognized rules of safety engineering. Nevertheless, during operation it is possible that harm might be caused to the user or third parties or that the installation or other property might get damaged. Therefore, the installation has to be handled according to specified operational use in perfect technical condition only. Safety endangering malfunctions cannot be tolerated during training and have to be removed immediately. The system is to be used only: for its intended purpose and in absolutely safe conditions.

Faults impairing safety must be rectified immediately!

© Festo Didactic GmbH & Co.KG. • prolog-factory

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General safety instructions

3.1.2

Safety precautions in standard operation

Put the installation into operation only, once all of the protection settings are completely functional. At least, before starting operation, check the installation for externally visible damages and for the reliability of the safety devices. Do not grip into the installation while in operation. Before circuit construction, circuit disassembly and circuit modification: switch off air pressure and power supply. General safety regulations are to be observed: DIN 58126 and VDE 0100.

3.1.3

Dangers due to electric current

As soon as maintenance is completed, check the function reliability of the safety devices. Only trained experts in electric or electronic engineering are permitted to carry out work on the electric supply system. The terminal boxes are to be kept closed at all times. Access must be permitted only under supervision of a member of the training staff. Do not activate electric limit switches manually during fault search. Tools are to be used. Only low voltage 24VDC is to be used.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

General safety instructions

3.1.4

Dangers due to pneumatic energy

Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt air pressure supply immediately. Caution! When the air pressure supply is activated, cylinders may move in or out. Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In this case, keep on holding the end of the tube. Do not exceed the permitted operating pressure. See data sheets. 3.1.5

Maintenance – Servicing – Malfunction removal

Carry out adjustments and inspections as instructed, in accordance with the specified intervals. Secure the compressed air and electricity supplies to prevent unintentional start-up. During inspections, maintenance and repair work, the machine must be deenergized, de-pressurized and secured against unexpected restart. All screw connections released during maintenance, inspection or repair work must be checked to ensure correct re-tightening. 3.1.6

Organizational measures

All existing safety devices must be checked at regular intervals.

© Festo Didactic GmbH & Co.KG. • prolog-factory

33

General safety instructions

3.2

Personnel

3.2.1

Notes on personnel

Basically two situations have to be considered, concerning matters on personnel. Activities during training operations Activities outside training operations

3.2.2

Training operations

Trainees are permitted to work with the machine only under strict supervision of an experienced person or an instructor. Activities of trouble-shooting and fault correction are to be checked by the instructor. Special care should be taken regarding safety aspects. 3.2.3

Outside training operations

Activities in the areas of maintenance, service and repair are to be carried out by only persons with appropriate technical qualifications.

3.3

34

Emergency stop system

There is no superior emergency system. Each station has its own emergency stop.

© Festo Didactic GmbH & Co.KG. • prolog-factory

General safety instructions

3.3.1

Safety symbols

In this manual the following danger designations and signs are being used.

This symbol indicates an immediate threat to a person’s health or life. DANGER ! Failure to pay attention to this symbol may result in serious health damage, which may even lead to life-threatening injuries.

This symbol emphasizes important information for correct machine handling. IMPORTANT Failure to pay attention to this symbol may result in damages to the machine or to its surroundings.

This symbol indicates operational tips and especially useful directions.

i

INFORMATION This symbol assists you to make optimal use of all of your machine’s functions.

© Festo Didactic GmbH & Co.KG. • prolog-factory

35

General safety instructions

36

© Festo Didactic GmbH & Co.KG. • prolog-factory

4

Commissioning

4.1

Transport

Care is to be taken that the transport of the stations is to be executed only by a suitable transport vehicle. The weight amounts up to 500 kg, depending on the station. The route of transport is to be cleared in advance, to be accessible to the transport vehicle. Installation of warning signs or barriers may be required. The transport boxes are to be opened with care, as additional components, such as computers may be contained in the delivery, which are to be protected from falling out.

i

Once the transport box has been opened and the possibly contained additional components removed, the station can be taken out to be transported to its destination by means of two fork-lifts or one fork-lift truck. Please check the stability of all of the profile connectors by means of an Allen key size 6. The connectors may have come loose during transport, due to inevitable vibration. Pay special attention to all overhanging components. Sensors and similar small parts are very easily damaged in case of improper transport. The stations are not to be picked up by or even under the mounted feet – increased risk of becoming trapped or contused. Check the station for any possible damaged once unpacked. The carrier and Festo Didactic are to be notified immediately of any damage. 4.1.1

Unpacking

Carefully remove the padding material in the container box when unpacking the station. When unpacking the station, make sure that none of the station assemblies have been damaged. Check the station for any possible damaged once unpacked. The carrier and Festo Didactic are to be notified immediately of any damage. 4.1.2

Scope of delivery

Check the scope of delivery against the delivery note and the order. Festo Didactic must be notified immediately of any discrepancies.

© Festo Didactic GmbH & Co.KG. • prolog-factory

37

Commissioning

4.2

Set up

4.2.1

General information

The installation is to be set up in a frost-free room with maximum relative air humidity of 70%. In countries with an atmospheric humidity over 70% and temperatures above 25 degrees Celsius are the premises to provide an air-conditioning system for constant surroundings conditions. To comply with the regulatory guidelines, sources of electrical interference such as welding plants, large motors and contactors are to be checked for electromagnetic compatibility in advance and screened where necessary. To ensure fault-free operation a load-bearing floor is required to avoid settling. Allow sufficient distance between the installation and the wall of the room. Any dust originating from construction work has to be kept off the installation (by covering). The log area is the first station of whole system which is built up. For the set-up of the system follow the instructions below: At first the room has to be measured, if not done so previously. The measures of all stations has to be marked roughly onto the floor space (i.e. with adhesive tape) to avoid shifting at a later stage. The station is placed in its final position, before it is balanced, by means of a spiritlevel. The table from the log area should be at a height of 785 mm.

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Commissioning

For a more simple room planning the complete installation design is shown in the following.

Installation design prolog factory

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Commissioning

Dimension drawing

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Commissioning

4.3

Commissioning

Commissioning of the system can ensue only, once all of the stations are connected to their definite position. 4.3.1

Pneumatic commissioning

The mechanical construction must be finished. At the beginning the stations have to be attached to the pneumatic system of the room. In most cases the maintenance unit is on the profile plate of the station. The coupling has a 5 mm nominal diameter. If the available system is equipped with 7.9 mm nominal diameter, it is possible to change the coupling of the maintenance unit with a greater one. (reducer 1/8 on 1/4 necessary). If this has been carried out, the stations can be provided with 600 kPA/6 bar and the pneumatic commissioning is realized. 4.3.2

Electric commissioning

The stations must be provided with electrical voltage now. The stations are provided with a power supply unit which is provided with a voltage of 110/230 V. The delivered cables have a completely protected norm plug, this must be plugged into an electrical socket protected sufficiently. Distribution strips are, enclosed to this also for the connection of other stations. If an extension for the cable is necessary for the distribution strip, this can to be executed only by a trained expert. The electrical socket must be protected, corresponding to the customer. The power supply (24 VDC) of the sensoric and the actuators of the station is provided in each case by means of a 2-pin cable. The voltage supply is a 24 V power supply unit, contained in the control cabinet or somewhere in the station. To avoid problems during the operational process, individual protection (16A) of the installation is recommended.

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Commissioning

4.3.3

Connecting communication cables

The PRO-LOG Factory covers all state of the art industrial communication levels and control technologies. The control levels are: Factory level: Order Entry Plant level: SCADA Device level: PLC, RC

The communication systems are:  Ethernet (LAN/WLAN) for communication between PLC and PC (see also following graphic)  RFID for communication between external I/O parts and PLC (see also following graphic)  Profibus for communication between Siemens PLC and Turck IO extension

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Commissioning

The communication inside the system takes place via Ethernet and Profibus DP. All connections are pluggable, the exception is the cable from the Drive unit, the cable is fixed in the drive unit and not pluggable.

Ethernet communication cables

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Commissioning

44

Position

Station

Ethernet address

1

MES PC

192.168.10.50

2

WinCC

192.168.10.51

3

Triple stack magazine station

192.168.10.1

4

LAN-switch

5

WLan router

192.168.101.2

6

Testing station with color sensor

192.168.10.2

7

Processing station

192.168.10.3

8

Pick and place station

192.168.10.4

9

Fluid muscle station

192.168.10.5

10

Storing station

192.168.10.6

11

Separating station

192.168.10.7

12

Sorting station

192.168.10.8

13

Commissioning station

192.168.10.20

14

Robotino 1

192.168.10.101

15

Robotino 2

192.168.10.102

© Festo Didactic GmbH & Co.KG. • prolog-factory

Commissioning

Profibus communication cables

Position

Station

Profibus DP address

1

Turk CPU commissioning station

DP # 3

2

Drive unit roboter

DP # 10

3

PLC commissioning station

DP # 2

4

Turk connecting unit log area

DP # 5

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Commissioning

RFID communication cables

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Position

Station

name

1

RFID sensor robot

1C1

2

RFID Card 1 for RFID sensor robot and slide 1

1K2

3

RFID Card 2 for RFID sensor slide 2 and slide 3

1K3

4

RFID sensor slide 1

1C2

5

RFID sensor slide 2

1C3

6

RFID sensor slide 3

1C4

© Festo Didactic GmbH & Co.KG. • prolog-factory

5

Operation

This chapter describes the necessary control units for starting and stopping the system, as well as operating with the system. 5.1

General operation notes

The stations require some rules of operation which should be observed. If they are not complied, faults in the processes are possible. Dangers for the physical health also cannot be excluded. It is recommended to observe the following rules strictly. 5.1.1

Behaviour rules

During the operation of the stations it is forbidden to grip in by hand. With larger audience a mechanical protection of the stations is necessary. Removing any cable under tension is forbidden. Water has to be kept away from the plant. 5.1.2

Operation rules

The stations only may be used by introduced persons. The operation has to be carried out according to the operating instructions. A pushing the different switches/push buttons of all control units unchecked has to be stopped. No work piece carriers may be taken by the system.

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Operation

5.2

Process description

Orders are entered and started in MES software. The commissioning station has to equip a pallet like defined in the order. It is possible to equip the pallet with 1-4 different work pieces. The commissioning station requests the necessary work pieces at the separating and testing station. The separating station gets the work pieces from the Storing station and the testing station gets the work pieces from the distribution station. There the work piece is checked for height and the color – the color must fit to the respective order, otherwise the work piece is sorted out on the slide. If the pallet is equipped, the robot takes the pallet and places it down at the outlay slide from the station. Robotino 1 takes the pallet from the slide and moves it to the high bay racking for temporary storage. From there robotino 2 moves the pallet to the respective outlay slide (Slide 1-3) of the system. The requirement therefore is that the slides are not occupied – in case the slides are occupied, it is necessary to put out the pallets by hand. The RFID sensors announce this in MES software, there the orders are deleted.

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Operation

5.2.1

Material flow

The processes and the material flow in PRO-LOG Factory is an image of a real production and distributing enterprise. There are buffers and magazines for the raw materials, and a storage for the single products. According to the customer orders, the products are transported JIS (just in sequence) to the commissioning robot. The pallets are stored in a high bay storage. The mobile robots are equipped with a fork on a telescope arm and work as a fork lift to reach the upper positions of the high-bay racking.

Position

Material flow

Station

1

Work pieces from MPS-System

MPS Stations

2

Equipped pallets to high bay storage

Robotino 1

3

Equipped pallets to outlay slides 1-3

Robotino 2

4

Empty pallets

Robotino 1

5

Sort out work pieces

Sorting Station

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Operation

Position numbers Robotino / orientation of pallets Position

Position number robotino

1

High bay rack position 1

2

High bay rack position 2

3

High bay rack position 3

4

High bay rack position 4

5

High bay rack position 5

6

High bay rack position 6

7

Commissioning station output slide position 7

8

Commissioning station input slide position 8

9

Log area input slide position 9 / Init position robotino 1

10

Log area output slide 3 position 10

11

Log area output slide 2 position 11

12

Log area output slide 1 position 12

13

Init position robotino 2

The black numbers are the work piece positions on the pallets. There you can see the orientation of the pallet.

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Operation

5.3

Robotino information and operation

Operation display robotino

Position

Function

Position

Function

1

Display line 1

6

Power button

2

Display line 2

7

Move upwards in menu

3

Display line 3

8

Enter Button

4

Display line 4

9

Move downwards in menu

5

Powers supply light

10

Move back on layer in menu

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Operation

5.3.1

General

The example is written for robotino 1, the operation of robotino 2 is equal. If there is no operation at the panel during start up the robotino, the display is going to stand by mode, press the Return button to bring back the panel to operation. If the charge of the accumulator is not more than 50% it is possible that the robotino doesn’t work exactly – in this case or in case of a crash press any button to stop the robotino. The external AP switch has following modes Left position = AP mode right position = Client mode

To guarantee constant 5V it is necessary to connect the gyroscope to the USB-Hub at the robotino.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Operation

The memory card with the system software has to be available in the slot of the robotino.

CF Card slot

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Operation

5.3.2

Start up

To start up the robotino, follow the instructions: 1.

2.

3. 4. 5. 6.

7.

Press Power button for more than 2 seconds. The power supply light is starting to lighten and the digits of the display are active. The controller is booting – wait till the display shows the robotinos name, the IP address and the accumulator charge condition. The accumulator of the robotino has to be loaded more than 50%. Load up the accumulators with help of the recharger cable for 2-3 hours. See (Line 4 in display) If not happened disconnect the charge cable from the robotino. Press the ENTER button and the system is coming to the main menu. Press the Arrow down Button to choose the line with the programs and press the ENTER button. Choose program ->Prolog_Vx.x_R1.rvw1 (for robotino 1) ->Prolog_Vx.x_R2.rvw2 (for robotino2) if the program is not available see chapter Download a program to robotino Be sure that the robotino is at the right starting position (See following picture – the lift has to stand like shown in the graphic – arrow announce direction) pay attention for the mark on the table.

Pos

Function Start

1

position robotino 1

Start 2

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position robotino 2

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Operation

8. 9.

Press ENTER button Robotino makes the reference move. After reference move the robot is in start position and is waiting for orders.

5.3.3

Switch off the robotino

To switch off the robotino press the power button for more than 3 sec. – The power supply light expires.

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Operation

5.4

Program start

For both robotinos: 1.

In the display-screen  If the light is not active, press enter  Press enter, you will be in the main menu  With the buttons, you have to go in the menu “programs”  Here, you will see one of the both programs :  ProLog_V1.1_R1  ProLog_V1.1_R2  R1 is the robot with the start-position 9.  R2 is the robot with the start-position 13.

 Position the robotino left-handed to the right position  Start the program with enter

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Operation

5.6 Program Upload robotino

The steps to upload the robotino’s program is the same for both robotinos. Make sure to download the right program:  

Robotino 1: Robotino 2:

Startposition 9, IP address 192.168.10.101 Startposition 13, IP address 192.168.10.102

Open the following program for robotino 1

Or for robotino 2

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Operation

In RobotinoView 2 select the tab Main program

Check the Robotino variable in the right column and set it accordingly:

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Robotino 1

-> Value 101

Robotino 2

-> Value 102

© Festo Didactic GmbH & Co.KG. • prolog-factory

Operation

Click on any sub program to get a list of directories on the right side of the program window

Double click on UPD connection PLC control. This opens a new window with the UDP connection settings. The IP address should be the same as the main plc. The ports are different for the two robotinos:

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Operation

Enter port 9180 for robotino 1:

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Enter port 9181 for robotino 2:

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Operation

Close the UPD connection control window and click on Upload project in the menu robotino

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Operation

The FTP client within RobotinoView opens and connects to Robotino. The IP address of the Robotino is entered in both IP address fields.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Operation

If successfully connected, the Robotino directories are displayed. Open the programs directory with a double click.

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Operation

Click on Upload current project to upload the opened program

The program is stored on the Robotino and can be started.

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Operation

5.5

Robotino-Pro-Log

Subprograms Name

Description

Init

Initialize several global variables for OPC and update the value of OPC-job_running via OPC.

InitFork

Initialize the fork. When the fork is down, set the global variable fork_isDown to true.

SetPosN

Set the global Variable pos_target_x, pos_target_y, and pos_target_phi, to posN_x, posN_y and posN_phi.

FindLine

Search the metal-line and set the global variable lineFound to true, when the Line is found. ( only with inductive sensors)

InitOdo

Save the orientation.

FindStop

Search the black band before the docking-position.

SetOdoN

Initialize the Odometry in saving the global Variable posN_x, posN_y and posN_phi.

CopyJob1

Save the order of the PLC.

CopyJob

Update the status of robotino via UDP

SetForkN

Set the global Variable fork_targetPosition to fork_posN_1 or Fork_posN_2.

LeaveDock

Leave the docking-position.

Drive

Drive to the Target-position defined with the global variables pos_target_x, pos_target_y, and pos_target_phi.

Positioning

The fork drives to the position defined with the global variable fork_targetPosition.

Fork FindLine-Odo

Search the metal-line and set the global variable lineFound to true, when the Line is found. (with the inductive sensor in the middle of the Robotino and with the odometry)

back

Initialize several global variables for UDP and update the value of udp-job_running via UDP.

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Operation

The Main Programm has several Parts, you can see that in the next schema:

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Operation

5.5.1

Explanations

Initialization       

5.5.2 1. 2. 3. 4.

5. 6. 7. 8.

Wait the connection. Initialize the fork. (fork is down) Save the target position. Find the metallic line. (only with inductive sensors) Save the orientation. Find the black band. Save the coordinate of the start-position.

Sequence to collect one Palette

Wait for a job and save this job. Save the right parameters: save the target-position for the Robotino and the fork. If the Robotino is already in the source-position:  The fork drives to the position fork_posN_1. (N=number of the source) If the Robotino is not already in the source-position then its drives to this position:  The Robotino leaves the dock.  In the same time, the Robotino drives to the target-position and do the following sequence:  Initialize the fork.  Save the origin of the fork.  The fork drives to the position fork_posN_1. (N=number of the source)  The Robotino finds the metallic line. (with inductive sensor and odometry)  The Robotino finds the black band. (with optical sensor) Save the right parameters: save the right coordinates in the Odometry and save the next target-position for the fork. The fork drives to the position fork_posN_2. That means the Robotino takes the palette in the source. The Robotino leaves the dock. Save the right parameters: save the target-position for the Robotino and the fork.

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Operation

9.

The Robotino drives to the sink-position:  In the same time, the Robotino drives to the target-position and do the following sequence:  Initialize the fork.  Save the origin of the fork.  The fork drives to the position fork_posN_2. (N=Number of the sink)  The Robotino finds the metallic line. (with inductive sensor and odometry)  The Robotino finds the black band. (with optical sensor) 10. Save the right parameters: save the right coordinates in the Odometry and save the next target-position for the fork. 11. The fork drives to the position fork_posN_1. That means the Robotino gives the palette in the sink. 12. If the Robotino is not in the storage warehouse (position-number between 1 and 6) then the sequence is finished. 13. If the Robotino is in the storage warehouse (position-number between 1 and 6) then the Robotino must drive to the start-position:  The Robotino leaves the dock.  Save the right parameters: save the target-position for the Robotino.  In the same time, the Robotino drives to the target-position and initialize the fork.  The Robotino finds the metallic line (with inductive sensor and odometry).  The Robotino finds the black band (with optical sensor).  Save the coordinate of the start-position.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Operation

5.5.3

Global Variables

Name

Description

Batterie

Value of the Batteries in Volt.

CurrentPos

Number of the current position (between 1 and 13).

Robotino

The Robotino´s number 101: starting position is pos09_1 102: starting position is pos13_1

dockLeft

True, when the dock is left.

fork_posN_1

Position of the fork in the position N.

Fork_posN_2

Position of the fork in the position N. Fork_posN_2 is always upside of fork_posN_1.

fork_posReached

True, when the fork is on the fork-targetPosition.

fork_targetPosition

The fork´s target-position.

gesamt

Intermediate variable in the calculation of the PI-controller in the subprogram FindStop.

lineFound

True, when the Robotino has found the metallic line and is aligned with this line.

udp_job_running

True, when the Robotino works about an order. False, when the Robotino is waiting an order.

job_sink

Sink-number of the next order transmitted via UDP to Robotino View.

job_source

Source-number of the next order transmitted via UDP to Robotino View.

posX_1_x

Coordinate of the position X_1 in the table-coordinates´ system.

posX_1_y

The position X_1 precedes the position X: the Robotino go first in the position X_1 and search the metal-line from this position.

posX_1_phi posX_x

Coordinate of the position X in the table-coordinates´ system.

posX_y

When the Robotino is docked, the odometry save the coordinate of the position X.

posX_phi

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Operation

Name

Description

pos_reached

True, when the Robotino is on the position pos_target_x, pos_target_y, and pos_target_phi of subprogram Drive.

pos_target_x

Coordinates of the target-position in the table-coordinates´ system.

pos_target_y pos_target_phi rearSensorHitLine

This variable is in the subprogram FindLine. It saves, if the inductive sensor has already once detected the metal-line or not.

stopFound

This variable is in the subprogram FindStop. True, when the Robotino is on the docking-position. That mean, when the optic sensor has detected the black band.

5.6

Data Exchange Variables

Name

Description

CurrentPos

Number of the current position (between 1 and 13).

job_running

True, when the Robotino works about an order. False, when the Robotino is waiting an order.

job_sink

Sink-number of the next order transmitted via UDP to Robotino View.

job_source

Source-number of the next order transmitted via UDP to Robotino View.

X

Coordinate of the Robotino (given by the odometrie) in the table-coordinates´ system.

Y Phi

These variables are present in the both programs.

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Operation

5.7

Log area information and operation

5.7.1

General

Position

Function

Positi on

Function

1

High bay rack

6

Robotino 2

2

Robotino 1

7

Output slide 1 (order 1)

3

Slide from commissioning station to log area

8

Output slide 2 (order 2)

4

Slide from Log area to commissioning station

9

Output slide 3 (order3)

5

Turk controller board

10

Input slide 1 (empty pallets)

There is no operation system for the log area. The control for the log area is done from the controller on the turk board. The board is supplied with 24 V from a extern power supply unit, be sure that the power supply unit is switched on. The lamps at the slides announce that a order is ready and the pallet is on the slide.

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Operation

The silver help lines on the table are for the Robotino, with a inductive sensor the Robotino follows the right edge of the line. The black markers are the stopping point for the Robotino, a optical sensor recognize the marker. The help lines are available at the slides and at the high bay rack.

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Position

Function

1

Silver help line (aluminum tape)

2

The robotino orientates at the right edge of the help line

3

Marker to stop the robotino in the right position

4

Direction of robotino to handing over a pallet to a slide

© Festo Didactic GmbH & Co.KG. • prolog-factory

Operation

High bay rack

Position

Function

1

High bay rack position 1

2

High bay rack position 2

3

High bay rack position 3

4

High bay rack position 4

5

High bay rack position 5

6

High bay rack position 6

5.7.2

Start up log area

Remove all parts from the outlay slides Remove all parts from high bay racking Fill up the Input slide with empty pallets

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Operation

5.8

Start up MPS stations

The operation of the stations is described in the stations manual – a short cut for operation to start up the system should be helpful. All stations have the same procedure. 5.8.1

Requirements

The reset process is the same for each MPS station. Execute the reset process at each station. The reset process is also to be executed after STOP- or EMERGENCYSTOP activation. 1. 2.

5.8.2

Fill up all magazines Clear all working positions

Reset process of MPS-stations

The MPS-stations can be started with the reset process, as following.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

Operation

5.9

Start up commissioning station

The operation of the station is described in the stations manual – a short cut for operation to start up the system should be helpful. 5.9.1

Requirements

Execute the reset process at the robot station. The reset process is also to be executed after STOP- or EMERGENCY-STOP activation. 1. 2. 3.

Clear all working positions, slides, the high bay rack at the log area and the pallet reception at commissioning station. Switch on power and air supply Key switch on Drive Unit to Auto/EXT Switch Teach Box to disable Switch on Drive Unit from robot

5.9.2

Reset process robot station

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Operation

5.10

Default mode

Default mode MPS

76

The default mode is helpful to check the complete system. If the default mode works without an error, all sensors and actors work faultless. In default mode all stations starting automatically if the START button at the stations are pressed and all stations are started without error. 1. 2. 3. 4.

Turn Key switch at all stations to default mode Fill up all magazines at MPS stations Start all stations with START button If the start button at the triple stack magazine is pressed, the station is starting to work. If the following station has now congestion jam, the first workpiece is separated and transported to the next station. The sequence is starting with a red workpiece, then a black, then silver and again a red workpiece etc. 5. The testing station checks the height from the workpiece. If the height is ok., the workpiece has the right orientation and is transported to the next station. If the height is not ok. the workpiece is sorted out on the slide 6. The processing station is processing the workpiece 7. The pick and place station implements an instrument into the workpiece 8. The Fluid muscle station is pressing the instrument into the workpiece 9. The storage station moves the red workpieces into the top row, the black workpieces into the middle and the silver workpieces into the lower row. If the following station is not occupied a workpiece is released from the storage. The station takes the color with the most workpieces in stock 10. The sorting station is sorting out the red workpieces to the first slide. The black and silver workpieces are transported to the commission station

© Festo Didactic GmbH & Co.KG. • prolog-factory

Operation

Default mode commissioning

1. 2. 3. 4. 5. 6. 7. 8. 9.

10.

11. 12. 13. 14.

Turn Key switch to default mode Place empty pallet to input slide at log area Start commissioning station with START button The robotino 1 takes the empty pallet from the input slide at log area (robotino pos. 9) and moves to input slide of the commissioning station (robotino pos. 8) The robot takes the pallet and moves to pallet reception position 1 If a workpiece is available from MPS line, the robot takes the workpiece from the conveyor. The workpiece is transported to first position on the empty pallet. If there is another workpiece, this is transported to second position on the empty pallet. etc. When the pallet is fully equipped, the robot takes to pallet to output slide of the commissioning station Robotino 1 is picking up the pallet from commissioning station and moves to the high bay rack at the log area. There the pallet is stored to shelf 1 of the high bay rack Robotino 2 is picking up the pallet from shelf 1 at the high bay rack and moves to output slide 1 from log area. There the pallet is made available for hand out of the system. This cycle is continued till all positions are tested once or the default mode is stopped. In the following the empty pallets from input slide at log area coming to pallet reception 2 then 3 and 4. If the first pallet is completely equipped, the workpieces coming to the pallets 2 then 3 and then to pallet 4. The equipped pallets are coming to high bay rack shelf 2. From there to output slide 2, from shelf 3 to slide 3 from shelf 4 to slide 1 etc.

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Operation

5.11

MES Mode

The MES mode is for automatic mode of the complete system. Operation and order handling is done by the MES Software. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

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Turn Key switch at all stations to MES mode (vertical – Auto) Fill up magazine at distributing stations (MPS) Prepare storage (MPS) equal the settings in MES Remove all workpieces from storage Remove all workpieces from working positions Remove all workpieces from conveyor positions Remove all workpieces from buffer at Log Area Place empty pallet to input slide at log area Start all stations with START button Operation is done by MES Software (See chapter process description) Announcement is done in WinCC

© Festo Didactic GmbH & Co.KG. • prolog-factory

6

6.1

WINCC

System information

The system is extended with a communication layer for using a SCADA system (Supervision, Control And Data Acquisition) like WinCC, for this system it is called "Level 2". For data exchange between SCADA system WinCC and the PLCs an Ethernet network is used. It is possible to configure the facility; single MPS-stations can be removed or relocated. If this is done, WinCC can conform to the real system. 6.1.1

Start-up WINCC

Before activating WinCC you have to make sure all programs have been downloaded to each PLC and all system cable connections are made: DC24V power supply 6bar system pressure I/O communication cables according to operation manual Ethernet cables connecting each PLC and computer Ethernet cables are connected with the Ethernet switch Ethernet switch is switched on Profibus cables connecting PLC commissioning with Turk board

System requirements: Windows XP with SP2/Vista, English or German Version with Internet Explorer V6.0 Ethernet-card installed to the computer WinCC V7.0 with SP1 with WinCC-Application Notice:

Please make sure that all software and hardware has been installed in this order!

© Festo Didactic GmbH & Co.KG. • prolog-factory

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WINCC

6.2

Use Runtime Application

Start screen with the overview of the system

Buttons and functions overview

80

Position

Function

1

Choose control panel of station

2

Announcement of chosen station

3

Announcement / operation of chosen control panel

4

Announcement in/outputs of chosen station (example with distribution station)

5

Announcement in/outputs of chosen station (example with testing station)

6

Announcement and choice of station at this position

7

Button to show details of the chosen station

8

Number and status of robotino, green = ready / yellow = busy

9

Button to show I/O´s of the different stations / Screen change to I/O screen

10

Button to show the main view / Screen change to overview screen

11

Button to announce alarm window

12

Button to announce “shut down WinCC”

© Festo Didactic GmbH & Co.KG. • prolog-factory

WINCC

I/O screen.

Buttons and functions I/O´s Position

Function

1

Choose I/O´s announcement of station / possible at all fields in I/O area

2

Announcement of chosen station

3

Announcement in/outputs of chosen station (example with distribution station)

4

Area for I/O´s of all stations, each field can be adjusted from the customer

5

If a station has a lot I/O´s, it is possible to switch to a second side to see the other I/O´s

6

Choose control panel from station / possible at all fields in control area, it is also possible to see robotino information

7

Announcement and operation with the chosen control panel

8

Area for control of all stations

9

Button to show I/O´s of the different stations / Screen change to I/O screen

10

Button to show the main view / Screen change to overview screen

11

Button to the alarm screen

12

Button to shut down WinCC

© Festo Didactic GmbH & Co.KG. • prolog-factory

81

WINCC

Alarm in I/O´s window Position

Function

1

Announcement of alarm at this station

2

Announcement of alarm somewhere in the system

3

Button to change to alarm window

Alarm class description  ERROR_L0 / fatal error, station doesn’t work anymore, solve problem, quit Error and reference move necessary  ERROR_L1 / still working and stops at the cycle end, quit error and push START button  ERROR_L2 / warning, station is still working, if necessary quit error

82

© Festo Didactic GmbH & Co.KG. • prolog-factory

WINCC

Alarm window warning Position

Function

1

Detailed alarm announcement / background grey for warning

2

Acknowledge and delete all alarms

3

Cancel alarm window without acknowledge the alarm

© Festo Didactic GmbH & Co.KG. • prolog-factory

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WINCC

Alarm window / error

84

Position

Function

1

Detailed alarm announcement / background red for error

2

Acknowledge and delete all alarms

3

Cancel alarm window without acknowledge the alarm

© Festo Didactic GmbH & Co.KG. • prolog-factory

WINCC

Shut down menu Position

Function

1

Choose function - Deactivate WinCC runtime and change to windows / WinCC is still active - Close project and shutdown WinCC to change to windows - Restart computer - Shutdown computer

2

Acknowledge function from shut down menu

3

Cancel shut down menu and change back to WinCC runtime

© Festo Didactic GmbH & Co.KG. • prolog-factory

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WINCC

Configuration window

86

Position

Function

1

Fault is announced (only in flash animation) / marked with the red frame

2

Description of fault

3

Confirm fault

© Festo Didactic GmbH & Co.KG. • prolog-factory

7

MES Software

The Manufacturing Execution System software is responsible for the order management. If the option MES is selected at the control panel, all orders are executed from this software. 7.1.1

Software requirements

 Windows 7 with newest service pack  Microsoft.Net framework V4.0 has to be installed

MES

Pos.

Description

1

Start the software with double click on the icon on desktop

At the first start the window from the firewall has to be confirmed.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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MES-Software

7.2

Settings

At the flag “TOOLS” it is possible to reload the system or to edit the options. If you choose the options, you can choose between common and communication.

Settings in common options Here you can adjust the common system, it is possible to        88

Delete all orders during start up Delete all buffers during start up Delete all finished orders during start up Set communication to active during start up Create Logfile edit time to refresh the overview Edit the order standard

© Festo Didactic GmbH & Co.KG. • prolog-factory

MES-Software

Settings in communication options

Here you can adjust the communication, it is possible to  Edit the port  Edit the quantity of clients

It is recommended that the user doesn’t change something in these options; otherwise, the program files have to be adjusted to the new settings.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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MES-Software

7.3

Operation

Start screen MES software The left side of the window is the order view and the right side is the main view, the main view is announced in real time. Pos.

Description

Pos.

Description

1

Change mode (see following screens)

6

Button to delete all orders

2

Change order announcement between list and

7

Button to disable all orders

8

Announcement of actual order

9

Announcement of actual order / with click in

tree 3

Announcement of order to produce a cylinder Background white = order not started Background yellow = order started Background blue = order ready Background red = error

4

Announcement of order to produce a pallet

field, a new window is opened 5

Announcement of workpiece in suborder Cylinder in red, black or silver

90

10

Announcement of actual order in new window (See screen commissioning order)

© Festo Didactic GmbH & Co.KG. • prolog-factory

MES-Software

Pos.

Description

Pos.

Description

11

Announcement of actual order in new window

16

Announcement of actual order in new window,

(See screen commissioning order) 12

Announcement of actual order in new window

it is possible to delete orders in the window 17

(See screen commissioning order) 13

Announcement of actual order in new window

green = online / red =offline 18

(See screen commissioning order) 14

Announcement of actual order in new window (See screen commissioning order)

15

Announcement of status guilty for all stations

New window with right click/See screen inventory

19

Announcement of actual order in new window (See screen commissioning order)

If a pallet is available at a penholder position, the position is marked green

© Festo Didactic GmbH & Co.KG. • prolog-factory

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MES-Software

Overview – orders shown as tree

Overview – orders shown as list

92

© Festo Didactic GmbH & Co.KG. • prolog-factory

MES-Software

Pos.

Description

Pos.

Description

1

Change mode (see following screens)

8

Announcement of actual order / cylinder or pallet are possible If the order is a commissioning order it is possible to choose the order, to define the output slide and to edit each position

2

Announcement of not enabled orders – with

9

The single positions from the order are

right click on order it is possible to enable or

announced here. It is possible to choose and

delete the chosen order

edit each single position

3

Delete selected order

10

Delete selected position

4

Add new order

11

Cancel all edits

5

Enable all orders

12

Save all edits

6

Delete all orders

13

Add new position

7

Announcement of actual order – it is possible to edit the start date and the customer

See also chapter create a New Order. (a reference guide to create a new order)

© Festo Didactic GmbH & Co.KG. • prolog-factory

93

MES-Software

Overview – orders shown for commissioning a palette

Overview – orders shown to produce a cylinder

94

© Festo Didactic GmbH & Co.KG. • prolog-factory

MES-Software

Analysing orders

Announcement of all produced orders. In the top area some choices can be done.

Analysing parts

Announcement of all produced parts.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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MES-Software

Configuration – resources

96

Pos.

Description

1

Change mode (see following screens)

2

Choose configuration area

3

Announcement of resources / chosen resource is blue

4

Announcement of functions from the chosen resource

5

Announcement of parameters

6

Picture of resource

© Festo Didactic GmbH & Co.KG. • prolog-factory

MES-Software

Configuration – production orders

Pos.

Description

1

Change mode (see following screens)

2

Choose configuration area

3

Announcement of order / chosen order is blue

4

Select order types: production (cylinder) commissioning (feed a pallet) templates (suborders)

5

Announcement of tasks of the chosen order

6

Announcement of parameters of the chosen task

© Festo Didactic GmbH & Co.KG. • prolog-factory

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MES-Software

Configuration – buffers

Pos.

Description

1

Change mode (see following screens)

2

Choose configuration area

3

Announcement of storage / each line is one shelf, the content is announced or editable, / the blue line is the active shelf

98

4

Save actual content

5

Choose resource of buffer

6

Choose buffer

7

Choose workpiece in shelf (red, black silver cylinder or pallet)

© Festo Didactic GmbH & Co.KG. • prolog-factory

MES-Software

Configuration – customer data

Pos.

Description

1

Change mode (see following screens)

2

Choose configuration area

3

Announcement / choice of customers

4

Create new customer

5

Delete chosen customer / If an order of the chosen customer is active, it is not possible to delete the customer

6

Announcement and insert field for customer data’s / the customer number is only editable when a new customer is created

7

Cancel the new customer data’s

8

Save new customer data’s

© Festo Didactic GmbH & Co.KG. • prolog-factory

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MES-Software

Configuration – generated orders

Pos.

Description

1

Change mode (see following screens)

2

Choose configuration area

3

Announcement and edit of generated orders, the chosen order is blue marked / all active orders get marked in the last column of the table

4

100

Save orders

© Festo Didactic GmbH & Co.KG. • prolog-factory

MES-Software

Inventory

Pos.

Description

1

Announcement of shelf / red, black or silver workpiece is possible

2

Choose sort of workpiece to edit workpiece in shelf

3

Cancel edits in inventory

6

Save edits in inventory

© Festo Didactic GmbH & Co.KG. • prolog-factory

101

MES-Software

Show commissioning order

Only announcement of commissioning order.

102

© Festo Didactic GmbH & Co.KG. • prolog-factory

MES-Software

7.4

Create a new order

7.4.1

Reference guide to create a new order

1.

Choose ‘New Orders’

2.

Click the Button ‘Add Orders’

3.

A new order, first set on commissioning, will be created

4. 5.

Set a start date and time Set a customer that is configured in the database

© Festo Didactic GmbH & Co.KG. • prolog-factory

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MES-Software

6.

Change the type of the order

7. 8. 9.

On a commissioning order a delay time and a output slide can chosen On a commissioning order also the parts must be chosen Positions can added or deleted with the Buttons

10. Press ‘Ok’ when finished 11. The Orders that are not enabled are listed in the TreeView

12. This Order can enabled, deleted or edited 13. If the Order is enabled it is Deleted from the New Orders and you can find it in the Overview

104

© Festo Didactic GmbH & Co.KG. • prolog-factory

MES-Software

7.5

Workaround Error on Situation: Storage Station 

Storage Station is on an Error 1. A part is lost on the way to the Separating Station 2. A part was not gripped



The position of the order is started and BUSY

Workaround: 1. Reset Storage Station 2. Check the Storage content in the MES Software (ProductionControler) and correct the content 3. Rightclick on the Position with the wrong state (picture)

And click reset position This position will be started again with first workorder 4. Start Storage Station in Automatic Mode (MES)

© Festo Didactic GmbH & Co.KG. • prolog-factory

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MES-Software

106

© Festo Didactic GmbH & Co.KG. • prolog-factory

8

8.1

Process description

Distributing Station

8.1.1

Standalone mode of Distributing Station

In standalone mode the Distributing Station distributes different types of workpieces one after another. First red, then black, silver, red again, and so on. If a magazine is empty, it automatically jumps to the next type of workpiece. Sequence of distribution

 First we select the color. For example if the station distributes a red previously, then it changes to black [spAuto].  According to the color of the workpiece to distributed, different cylinders will be extended [spExtRed / spExtBlack / spExtSilver]. If the magazine is empty, the station will be on Idle state [stIdle].  When the workpiece arrives at the end of conveyor, the cylinder will be retracted [spRetract].  Simultaneously the conveyor will stop 1 sec after the workpiece passes the sensor at the end of conveyor [spStopConv].  Then the station will be on Idle state [spIdle].

spIdle Station on Idle state Station in standalone mode, and next station is free

spAuto Change color to the next.

Red, and magazine 1 is not empty

Black, and magazine 2 is not empty

Silver, and magazine 3 is not empty

Else

spExtRed

spExtBlack

spExtSilver

spMagEmpty

Extend cylinder at magazine 1

Extend cylinder at magazine 2

Extend cylinder at magazine 3

Empty: Jump back to spIdle

Workpiece at conveyor end (-3B1)

spRetract

spWait1s

Retract the cylinder at the magazine

Empty: Wait 1 sec

Cylinder is retracted

1 sec later

spStopConv Stop the conveyor motor

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Process description

8.1.2

MES mode of Distributing Station

In MES mode the Distributing Station cyclically asks for the task from the MES server (in every second). It sends, the colors it has, and gets a task for one of these colors. Sequence of distribution









  



108

Firstly the station asks for the next task. It is done by a program called MES_CyclicRequestForOrder. This program asks for a task, if the station is on Idle state [spIdle]. It means the station sends an “Ask for a Task” message (M100.1). If it has a workpiece with the selected color, it sends a “Task Started” message (M100.10). [spRedStart / spBlackStart / spSilverStart]. According to the color of the workpiece to distributed, different cylinders will be extended [spExtRed / spExtBlack / spExtSilver]. When the workpiece arrives at the end of conveyor, the “Task Finished” message (M101.1) will be sent by the station to the MES server [spSendFinished]. Then the cylinder will be retracted [spRetract]. Simultaneously the conveyor will stop 1 sec after the workpiece passes the sensor at the end of the conveyor [spStopConv]. After that the station waits for next station [spWaitForValidation]. It has to wait for validation, because, if the validation fails, it has to reproduce the part. Then the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

spIdle Station on Idle state

MES_CyclicRequestForOrder Cylcically request for task in every second.

Station in MES mode, task received, and next station is free

spMES Registrate the color

Red, and magazine 1 is not empty

Black, and magazine 2 is not empty

Silver, and magazine 3 is not empty

Else

spRedStart

spBlackStart

spSilverStart

spMagEmpty

Entry: Send "Task Started" (M100.10)

Entry: Send "Task Started" (M100.10)

Entry: Send "Task Started" (M100.10)

Empty: Jump back to spIdle

Answer received

Answer received

Answer received

spExtRed

spExtBlack

spExtSilver

Extend cylinder at magazine 1

Extend cylinder at magazine 2

Extend cylinder at magazine 3

Workpiece at conveyor end (-3B1)

spSendFinished Entry: Send "Task Finished" (M101.1) Answer received

spRetract

spWait1s

Retract the cylinder at the magazine

Empty: Wait 1 sec

Cylinder is retracted

1 sec later

spStopConv Stop the conveyor motor

spWaitForVali... Empty: Wait for next station (validation) Next station finished

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Process description

8.2

Testing Station

8.2.1

Standalone mode of Testing Station

In standalone mode the Testing Station checks only the orientation of the workpieces. If the workpiece is hole side up, then the station transports it to the next station. If the workpiece is hole side down, then the station will transport it to the waste slide. Sequence of validation

  

If a workpiece arrives, the station switches the conveyor belt motor on, and waits for 1 sec [spConveyorOn] Then the station checks the orientation of the workpiece with a laser sensor [spCheck]. If the orientation of the workpiece is not ok: o o o

The station extends the gate to the waste slide [spExtendGate]. The stopper cylinder will be retracted [spRetrStopper]. Then the station waits until the workpiece arrives on the waste slide [spWait3B1].

If the orientation of the workpiece is ok: o o o o  

110

The station waits for the next station [spWaitNext]. The stopper cylinder will be retracted [spRetrStopper]. The station waits until the next station starts working [spWaitNotNext]. Then waits for 1 sec more [spWait1s].

The gate is retracted (if it was extended), the stopper is extended, and the conveyor motor is stopped [spStop]. After the gate arrives to initial state, the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

spIdle Station in Idle state Station in standalone mode, and workpiece arrived

spConveyorOn Switch on conveyor belt motor 1 sec later

spCheck Check orientation

Orientation is ok

Orientation is not ok

spWaitNext

spExtendGate

Empty: Wait until next station is free

Extend gate to the waste slide

Next station is free

Save the workpiece type

Gate extended

spRetrStopper Retract the stopper cylinder

Orientation was ok

Orientation was not ok

spWaitNotNext

spWait3B1

Wait until next station starts working

Empty: Wait until work piece on slide

Next station is free

workpiece on slide

spWait1s Empty: Wait 1 sec After 1 sec

spStop Retr. Gate, ext. Stopper, stop conveyor Gate in intial state

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Process description

8.2.2

MES mode of Testing Station

In MES mode the Testing Station asks for the color from the MES server. If the workpiece is hole side down, or the color does not match, the station will transport it to the waste slide. If the color and orientation are good, the station transports the workpiece to the next station. Sequence of validation

    

If a workpiece arrives, the station switch the conveyor belt motor on, and waits for 1 sec [spConveyorOn] Then asks for task. It sends the “Ask for a Task” message (M100.1) [spAskForOrder]. If the station gets a task, it sends back a “Task Started” message (M100.10) [spSendStarted]. Then the station checks the workpiece with the color sensor, and laser sensor [spCheck]. If the color or the orientation of the workpiece is not ok, or there is no task: o o o o

The station extends the gate to the waste slide [spExtendGate]. The stopper cylinder will be retracted [spRetrStopper]. Then the station waits until the workpiece arrives on the waste slide [spWait3B1]. Simultaneously the station sends “Task Finished with Error” message (M101.1 with error) [spSendError]

If the color and the orientation of the workpiece are ok: o o o o o  

112

The station waits for the next station [spWaitNext]. The stopper cylinder will be retracted [spRetrStopper]. The station waits until the next station starts working [spWaitNotNext]. Then waits for 1 sec more [spWait1s]. Then the station sends “Task Finished” message (M101.1) [spSendFinished].

The gate is retracted (if it was extended), the stopper is extended, and the conveyor motor is stopped [spStop]. After the gate arrives to initial state, the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

spIdle Station on Idle state Station in MES mode, and workpiece arrives

spConveyorOn Switch conveyor belt motor on 1 sec later

spAskForOrder Entry: Send "Ask for a Task" (M100.1) Answer received

spSendStarted Entry: Send "Task Started" (M100.10) Answer received

spCheck Check color and orientation

Orientation and color are ok

Orientation or color is not ok, or no task

spWaitNext

spExtendGate

Empty: Wait until next station is free

Extend gate to the waste slide

Next station is free

Registrate the workpiece type

Gate extended

spRetrStopper Retract the stopper cylinder

Orientation and color were ok

Orientation or color was not ok , or no task

spWaitNotNext

spWait3B1

spSendError

Wait until next station starts working

Empty: Wait until workpiece on slide

Entry: Send "Task Finished with error"

Next station is free

workpiece on slide

(M101.1 with error)

Answer received

spWait1s Empty: Wait 1 sec After 1 sec

spSendFinished Entry: Send "Task Finished" (M101.1) Answer received

spStop Retr. Gate, ext. Stopper, stop conveyor Gate in intial state

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Process description

8.3

Processing Station

8.3.1

Standalone mode of Processing Station

In standalone mode the Processing Station checks the hole in the workpiece, and if it is hole side up, the station drills a hole in it. After that it will be transported to the next station. Only one workpiece can be on the station in the same time. The Processing Station does the same in MES mode. Sequence of processing

      

If a workpiece arrives, the station waits for 1 sec [spWaits1s]. Then the indexing table rotates one step [sp_rotate1_1, spRotate2_1]. Then the testing unit moves down, and waits for 1 sec to reach the bottom [spTesting]. The station checks the hole [spCheck]. Then it registrates the type of workpiece [spOk / spNotOk]. The testing unit moves up [spTestingUp]. Then the indexing table rotates one step again[sp_rotate1_2, spRotate2_2]



If the orientation of the workpiece was ok: o o o o o

    

114

Fixes the workpiece [spFix]. Switches the drill motor on, and the drilling unit moves down [spDrillDown]. The drilling unit moves up [spDrillUp]. Switches the drill motor off [spDrillOff]. Releases the workpiece [spRelease].

Then the indexing table rotates one step again [sp_rotate1_3, spRotate2_3]. Waits until the next station is free [spWaitNext]. Ejects the workpiece to the next station [spEject]. Retracts the eject solenoid [spStop]. The station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

2

1

spIdle Station on Idle state

Hole side up

Hole side down

spFix

Workpiece arrives

Fix the workpiece

spWait1s Empty: Wait 1 sec

After 1 sec

spDrillDown

1 sec later

Switch the drill on, and drill unit moves down

spRotate1_1 Give start signal for rotation of table

Drill unit is in bottom position

spDrillUp

Table is not in position

Drill unit moves up

spRotate2_1 Reset start signal for rotation of table

Drill unit is in top position

spDrillOff

Table is in position

Switch the drill motor off

spTesting Testing unit moves down

spRelease

After 1 sec

Release the workpiece

spCheck Empty: Check the hole

spRotate1_3 Hole side up

Hole side down

spOk

spNotOk

Set workpiece type to ok

Set workpiece type to not ok

Give start signal for rotation of table Table is not in position

spRotate2_3 Reset start signal for rotation of table

spTestingUp Testing unit moves up After 1 sec

spRotate1_2 Give start signal for rotation of table Table is not in position

spRotate2_2 Reset start signal for rotation of table Table is in position

2

© Festo Didactic GmbH & Co.KG. • prolog-factory

Table is in position

spWaitNext Empty: Wait until next station is free Next station is free

spEject Eject workpiece to next station After 1 sec

spStop Retract the eject solenoid

1

115

Process description

8.4

Pick & Place Station

8.4.1

Standalone mode of Pick & Place Station

In standalone mode the Pick & Place Station inserts a clock, a thermometer or a hygrometer into the workpiece. The handling unit grips the instrument with a vacuum, and inserts it on the workpiece. The Pick & Place Station does the same in MES mode. Sequence of insertion

                

116

If a workpiece arrives the station extends the separator [spSepExt]. Then starts the conveyor [spConvOn]. After that it waits for 1 sec [spWait1s]. Then switch the conveyor off [spConvOff]. The handling unit moves down to the instrument [spDown]. The station switch the vacuum on to grip the instrument [spVacuumOn]. If the skipping of vacuum error is active ( xSkipVacError) then it will wait for 2 sec [spWait2s], or wait until the signal comes from the vacuum sensor. Then the station moves up with the instrument [spUp]. Extends the horizontal cylinder [spExtend]. Moves down to the workpiece to insert the instrument on it [spDown2]. Switches the vacuum off [spDrop]. Moves up [spUp2]. Retracts the horizontal cylinder [spRetract]. Simultaneously if the next station is free [spWaitNext], retracts the separator, and switches the conveyor motor on [spSepRetr]. Waits for 1 sec for workpiece transport [spWait1s_2]. Switches the conveyor off [spConvOff2]. Then the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

2

1

spIdle spExtend

Station on Idle state

Extend the horizontal cylinder Workpiece arrives Horizontal cylinder is extended

spSepExt

spDown2

Extend the separator

Move down with the instrument Not in upper position

spConvOn

spDrop

Switch the conveyor motor on Workpiece passes the sensor before the separator

Switch the vacuum off (drop the instrument) No vacuum

spWaits1s

spUp2

Empty: Wait 1 sec

Move up 1 sec later In upper position

spConvOff Switch the conveyor motor off

spRetract

spWaitNext

Retract the horizontal cylinder

Empty: Wait for next station

spDown

Next station is free

Move down to instrument

spSepRetr

Vertical cylinder is not in upper position

Switch conveyor on, retract separator

spVacuumOn Switch vacuum on

Workpiece at conveyor end

spWaits1s_2 Vacuum sensor is on

Skipping the vacuum error is active (xSkipVacError)

spWait2s Empty: Wait 2 sec

2 sec later

Empty: Wait 1 sec

1 sec later

spConvOff2 Switch the conveyor motor off

spUp Move up with the instrument In upper position

2

© Festo Didactic GmbH & Co.KG. • prolog-factory

1

117

Process description

8.5

Fluidic Muscle Press Station

8.5.1

Standalone mode of Fluidic Muscle Press Station

In standalone mode the Fluidic Muscle Press Station presses the instrument into the workpiece. It uses a pneumatic muscle for pressing. The Fluidic Muscle Press Station does the same in MES mode. Sequence of pressing

           

118

If a workpiece arrives, the station waits for 2 sec [spWait2s]. Then closes the gripper and waits for another 1 sec [spClose]. Rotates to the processing position [spRotateProc]. The pressing unit moves down [spPressDown]. If the pressure is reached, the unit moves up [spPressUp]. Rotates to the downstream station [spRotateDown]. Then waits for the next station [spWaitDown]. If the next station is free, the horizontal cylinder is extended to the downstream station [spMoveDown]. The station opens the gripper [spOpen], and waits for 1 sec. The horizontal cylinder is retracted to the upstream station [spMoveUp]. Rotates to the upstream station [spRotateUp]. If the station reaches the initial position, the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

spIdle Station on Idle state

Workpiece arrives

spWaits2s Empty: Wait 2 sec

2 sec later

spClose Close the gripper

1 sec later

spRotateProc Rotate to the processing position Rotary drive at processing position

spPressDown Pressing unit moves down Pressure reached

spPressUp Pressing unit moves up 2 sec later

spRotateDown Rotate to the downstream station Rotary drive at downstream station position

spWaitDown Wait for next station

Next station is free

spOpen Open the gripper

1 sec later

spMoveUp Retract the horizontal cylinder Liner drive at upstream position

spRotateUp Rotate to upstream position Rotary drive at upstream station position

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Process description

8.6

Storing Station

8.6.1

Standalone mode of Storing Station

In standalone mode there are two tasks (insertion, removal). The station switches between each of the tasks one after the other. The first task is inserting the incoming workpiece into the storage. Each colors are sorted on different shelves (from the top: red, black, silver). The station searches from the right side for an empty tray. If there is no free place for the workpiece, it will be transported to the next station. The second task is the removal. If the next station is free, the Storing Station searches for the color, which occurs the most, and transports it from the storage to the next station. The station searches from the right side for a workpiece. Sequence of insertion



 

If a workpiece arrives the station moves above the workpiece [spMoveAboveIn_c1]. It clears the number of failed color checks [spCheckNum0_c1]. (It should count the number of fails of color checks, because if it failed three times in a row, there is a problem with the color sensor, and the station has to go to error state.) Then the station extends the horizontal cylinder [spExtend_c1]. Then it checks the color [spCheckColor_c1].



If the color check fails:



o o o      

120

Retracts the horizontal cylinder, and increases the number of failed color checks [spRetract_c1]. Then checks whether there is still a workpiece or not [spCheckWp_c1]. If there is still a workpiece jumps back before color check [spExtend_c1], else the station jumps back to Idle state [spIdle].

Then the station search for an empty tray for workpiece [spSearchIPlace]. If there is no free place, the workpiece will be transported to the next station. Moves down to the workpiece [spMoveIn_c1]. Closes the gripper [spClose_c1]. Moves up with the workpiece [spMoveAboveIn_c2]. Retracts the horizontal cylinder [spRetract_c2]. Moves above the empty tray, or above the input of the next station [spMoveAboPlace_c1].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description



If the workpiece was transported to the next station : o

Retracts Waits until the next station is free [spWaitNext_c1].

  

Extends the horizontal cylinder [spExtend_c2]. Moves to the tray or to the input of the next station [spMovePlace_c1]. Opens the gripper [spOpen_c1].



If the workpiece was transported to a tray : o

 

Registrates the insertion [spRegIns_c1].

Retracts the horizontal cylinder [spRetract_c3]. Then the station will be on Idle state [spIdle]. 1

2

spIdle spRetract_c2

Station on Idle state

Retract horizointal cylinder

Station in standalone mode, insertion is selected, and workpiece arrives

Horizontal cylinder retracted

spMoveAb.In_c1

spMoveAb.Pl._c1

Move above the upstream station pos.

Move above the place Motion finished Motion finished

spCheckNum0_c1

Insertion into the storage not to the next station

Reset the number of color checks

Wait for next station

spExtend_c1 Extend the horizontal cylinder

Next station is free

Horizontal cylinder extended

spExtend_c2

spCheckColor_c1

Extend the horizontal cylinder

Check and registrate the type of the wp.

Horizontal cylinder extended

1 sec later

spMovePlace_c1

Workpice color was detected

spSearchIPlace Search free place for insertion

Else

spWaitNext_c1

If there is no free place select the next station for insertion.

Else

Move to the place

spRetract_c1 Retract horizointal cylinder

Motion finished In entry action increase the number of color checks

Horizontal cylinder retracted

spMoveIn_c1

spCheckWp_c1

Move to the upstream station position

Empty: Check if there is a workpice or not

Open the gripper

1 sec later If inserted into the storage

Motion finished

spClose_c1

There is no workpiece (it was removed)

spOpen_c1

There is a workpiece

Else

spRegIns_c1 Registrate the insertion

Close the gripper

1 sec later

spMoveAb.In_c2 Move above the upstream station pos.

spRetract_c3 Retract horizointal cylinder Horizontal cylinder retracted

Motion finished

1

2

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Process description

Sequence of removal

  

If the removal is active the station selects the color, which occurs the most [spSelColor_d1]. Then it searches for a tray, which has a workpiece with the same color [spSearchRPlace]. If there is not a workpiece in the storage with the specific color of the order: o

           

122

The station jumps back to Idle state [spIdle].

Then the station moves to the workpiece [spMovePlace_d1]. Extends the horizontal cylinder [spExtend_d1]. Closes the gripper [spClose_d1]. Lifts up the workpiece [spMoveAbovePlace_d1]. Registrates the removal [spRegRam_d1]. Retracts the horizontal cylinder [spRetract_d1]. Moves above the input of the next station [spMoveAboveOut_d1]. Extends the horizontal cylinder [spExtend_d2]. Moves to the input of the next station (uses only the linear axes) [spMoveOutLin_d1]. Opens the gripper, drops the workpiece [spOpen_d1]. Retracts the horizontal cylinder [spRetract_d2]. Then the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

1

2

spIdle spRegRem_d1

Station on Idle state Station in standalone mode, removal is selected, and the storage is not empty

Registrate the removal

spSelColor_d1 spRetract_d1

Select color (which occurs the most)

Retract the horizontal cylinder Horizontal cylinder retracted

spSearchRPlace

spMo.Ab.Out_d1

Search for the selected color in storage

If there is a wp. with the selected color

Move above downstream station Else

Motion finished

spMovePlace_d1

spExtend_d2

Move to the place

Extend the horizontal cylinder

Motion finished

Horizontal cylinder extended

spExtend_d1

spMo.OutLin_d1

Extend the horizontal cylinder

Move to downstream station (only linear)

Horizontal cylinder extended

Motion finished

spClose_d1

spOpen_d1

Close the gripper

Open the gripper

1 sec later

1 sec later

spMoveAb.Pl._d1

spRetract_d2

Move above the place

Retract the horizontal cylinder

Motion finished

1

© Festo Didactic GmbH & Co.KG. • prolog-factory

Horizontal cylinder retracted

2

123

Process description

8.6.2

MES mode of Storing Station

In MES mode there are two tasks (insertion, removal). The station switches between each of the tasks one after the other. The first task is inserting the incoming workpiece into the storage. After the station detects the color, it asks for a task from MES server. If there is an order for the specific color of the workpiece, it will serve it. If there is no order for the color, the station asks the MES server for an empty tray, and inserts the workpiece into this tray. If there is no free place, the workpiece will be transported to the next station. The second task is the removal. If the next station is free, the Storing Station asks the MES server for an order. If there is an order, the station transports it from the storage to the next station. Sequence of insertion



 

If a workpiece arrives the station moves above the workpiece [spMoveAboveIn_a1]. It clears the number of failed color checks [spCheckNum0_a1]. (It should count the number of fails of color checks, because if it failed three times in a row, there is a problem with the color sensor, and the station has to go to error state.) Then the station extends the horizontal cylinder [spExtend_a1]. Then it checks the color [spCheckColor_a1].



If the color check fails:



o o o 

124

Retracts the horizontal cylinder, and increases the number of failed color checks [spRetract_a1]. Then checks whether there is still a workpiece or not [spCheckWp_a1]. If there is still a workpiece jumps back before color check [spExtend_a1], else the station jumps back to Idle state [spIdle].

Then the station asks for the next order from the MES (M100.1) [spAskForOrder_a1).

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description



If there is an order for the station:

o

It asks for the parameters of the order (M100.21) [spAskForParameters_a1]. Then registrates the color from the answer [spSaveColor_a1].

o

If the color of workpiece and order match:

o

                    

The stations ends “Task Started” message (M100.10) [spSendStarted_a1] Moves to the workpiece [spMoveIn_a1]. Closes the gripper [spClose_a1]. Lifts up the workpiece [spMoveAboveIn_a2]. Retracts the horizontal cylinder [spRetract_a2]. Moves above the input of next station [spMoveAboveOut_a1]. Waits until the next station is free [spWaitNext_a1]. Extends the horizontal cylinder [spExtend_a2]. Moves to the input of the next station (use only the linear axes) [spMove.OutLin_a1]. Opens the gripper, drops the workpiece [spOpen_a1]. Retracts the horizontal cylinder [spRetract_a3]. Send a “Task finished” message (M101.1) [spSendFinished_a1]. Then the station jumps back to Idle state [spIdle].

Then the station asks for an empty tray for the workpiece from MES [spSearchMESIPlace]. Then the station calculates the row and column number from the tray number [spCalcColRowI_a1]. If there is no empty tray, the workpiece will be transported to the next station. Moves down to the workpiece [spMoveIn_a2]. Closes the gripper [spClose_a2]. Moves up with the workpiece [spMoveAboveIn_a3]. Retracts the horizontal cylinder [spRetract_a4]. Moves above the empty tray, or above the input of the next station [spMoveAboPlace_a1]. If the workpiece was transported to the next station : o

Retracts Waits until the next station is free [spWaitNext_a4].

  

Extends the horizontal cylinder [spExtend_a3]. Moves to the tray or to the input of the next station [spMovePlace_a1]. Opens the gripper [spOpen_a2].



If the workpiece was transported to a tray : o o

 

Registrates the insertion [spRegIns_c1]. And simultaneously registrates the insertion in MES(M100.31) [spRegInsMES].

Retracts the horizontal cylinder [spRetract_a5]. Then the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Process description

spIdle Station on Idle state Station in MES mode, insertion is selected, and workpiece arrives

spMoveAb.In_a1 Move above the upstream station pos. Motion finished

spCheckNum0_a1 Reset the number of color checks

spExtend_a1 Extend the horizontal cylinder Horizontal cylinder extended

spCheckColor_a1 Check and registrate the type of the wp. 1 sec later Workpice color was detected

Else

spRetract_a1 Retract horizointal cylinder

In entry action increase the number of color checks

Horizontal cylinder retracted

spCheckWp_a1 Empty: Check if there is a workpice or not

There is no workpiece (it was removed)

spAskForOrder_a1

There is a workpiece

Entry: Ask for an order (M100.1) Answer received There is no task for the station

Else

spAskForPara._a1 Entry: Ask for param. (M100.21) Answer received

spSaveColor_a1 Registrate color from answer

Task and workpiece color do not match

Else

spSearchMESIPla.

spSendStarted_a1

Search free place for insertion

Entry: Send "Task Started" (M100.10)

Answer received

spCalcColRowI_a1 Calculate the row and column number

If there is no free place select the next station for insertion.

Answer received

spMoveIn_a1 Move to the upstream station position Motion finished

1

126

2

3

4

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

1

2

3

spMoveIn_a2

spClose_a1

Move to the upstream station position

Close the gripper

Motion finished

4

1 sec later

spClose_a2

spMoveAb.In_a2

Close the gripper

Move above the upstream station pos.

1 sec later

Motion finished

spMoveAb.In_a3

spRetract_a2

Move above the upstream station pos.

Retract horizointal cylinder Horizontal cylinder retracted

Motion finished

spRetract_a4

spMov.Ab.Out_a1

Retract horizointal cylinder

Move above the downstream station pos.

Horizontal cylinder retracted

Motion finished

spMoveAb.Pl._a1

spWaitNext_a1

Move above the place

Move above the place

Motion finished

Next station is free

Insertion into the storage not to the next station

spExtend_a2

Else

Extend the horizontal cylinder

spWaitNext_a2

Horizontal cylinder extended

Move above the place

Next station is free

spMov.OutLin_a1 Move to downstream station (only linear)

spExtend_a3

Motion finished

Extend the horizontal cylinder

spOpen_a1

Horizontal cylinder extended

Open the gripper

spMovePlace_a1

1 sec later

Move to the place

spRetract_a3 Retract horizointal cylinder

Motion finished

spOpen_a2

Horizontal cylinder retracted

Open the gripper

spSendFinish._a1 Entry: Send "Task Finished" (M101.1)

1 sec later If inserted into the storage

spRegIns_a1

spRegInsMES

Registrate the insertion

Entry: Registrate the insertion in MES

Else

Answer received

spRetract_a5 Retract horizointal cylinder Horizontal cylinder retracted

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Process description

Sequence of removal

  

If the removal is active, and there is an order the station asks for the parameters of the order (M100.21) [spAskForParameters_b1]. Then it asks from the MES for a tray, which has a workpiece with the same color (M100.30) [spSearchRPlace]. If there is not a workpiece in the storage with the specific color of the order: o

              

128

The station jumps back to Idle state [spIdle].

Then the station sends a “Task started” message (M100.10) [spSendStarted_b1]. Moves to the workpiece [spMovePlace_b1]. Extends the horizontal cylinder [spExtend_b1]. Closes the gripper [spClose_b1]. Lifts up the workpiece [spMoveAbovePlace_b1]. Registrates the removal [spRegRam_b1]. And simultaneously registrates the removal in MES [spRegRemMES]. Retracts the horizontal cylinder [spRetract_b1]. Moves above the input of the next station [spMoveAboveOut_b1]. Extends the horizontal cylinder [spExtend_b2]. Moves to the input of the next station (uses only the linear axes) [spMoveOutLin_b1]. Opens the gripper, drops the workpiece [spOpen_b1]. Retracts the horizontal cylinder [spRetract_b2]. Sends a “Task finished” message (M101.1) [spSendFinished_b1]. Then the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

1

2

spIdle Station on Idle state Station in MES mode, removal is selected, and there is an order

spRegRem_d1

spRegRemMES

Reistrate the removal

Entry: Registrate the removal in MES

spAskForPara._b1

Answer received

Entry: Ask for parameters (M100.21)

spRetract_b1

Answer received

Retract the horizontal cylinder

spSea.MESRPl._b1

Horizontal cylinder retracted

Entry: Search for tray with MES

spMo.Ab.Out_b1

Answer received

Move above downstream station

spSearchMESRPla. Entry: Ask for place from MES (M100.30)

Motion finished

spExtend_b2

Answer received

Extend the horizontal cylinder

spCal.Co.Ro.R_b1

Horizontal cylinder extended

Calculate the column and row from param.

spMo.OutLin_b1 If there is a wp. with the selected color

spSendStarted_b1 Entry: Send "Task Started" (M100.10) Answer received

spMovePlace_b1 Move to the place

Motion finished

spExtend_b1 Extend the horizontal cylinder Horizontal cylinder extended

spClose_b1

Else

Move to downstream station (only linear) Motion finished

spOpen_b1 Open the gripper

1 sec later

spRetract_b2 Retract the horizontal cylinder Horizontal cylinder retracted

spSendFinish._b1 Entry: Send "Task Finished" (M101.1) Answer received

Close the gripper

1 sec later

spMoveAb.Pl._b1 Move above the place

Motion finished

1

© Festo Didactic GmbH & Co.KG. • prolog-factory

2

129

Process description

8.7

Separating Station

8.7.1

Standalone mode of Separating Station

In standalone mode the Separating Station transports the black and silver workpieces to the Robot Station with the separator gate, and transports the red workpiece to the Sorting Station. In this case the station uses all sensors, so we can check whether they are working or not. Sequence of separation

   

After a workpiece arrives the station waits for 2 sec [spWait2s]. (It waits for the Storing Station.) Then switches the main conveyor motor on [spConv1On]. After the workpiece arrives to check point it waits for 1 sec [spWait1s]. Then it checks the color and material [spCheck].



If the color of the workpiece is black or silver: o

Extends the separator gate, switches the perpendicular conveyor on, and registrates that the workpiece was good [spExtGate].

If the color of the workpiece is red: o     

130

Registrates that the workpiece was not good [spNotOk].

Then the station waits for the next station [spWaitNext]. After the next station is free, the station retracts the stopper [spRetrStop]. After the workpiece arrives at the end of either of conveyor, the station waits for 2 sec [spWait2s_2]. 2 sec later it retracts the separator, extracts the stopper and stops the conveyors [spStop]. After that the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

spIdle Station on Idle state Station in MES mode, and workpiece arrives

spWait2s Empty: Wait 2 sec

2 sec later

spConv1On Switch the main conveyor on Workpiece at check position

spWait1s Empty: Wait 1 sec

1 sec later

spCheck Check and reg. the type of the workpiece

Workpiece is black or silver

Else

spExtGate

spNotOk

Extend the separator and switch conv. 2 on

Save that the workpiece was not good

Registrate the workpiece type

Separator is not retracted

spWaitNext Wait until next station is free

Wait for sorting or for the robot buffer.

Next station is free

spRetrStop Retract the stopper Workpiece arrives at the end of any conveyor

spWait2s_2 Empty: Wait 2 sec

2 sec later

spStop Retr. Gate, ext. Stopper, stop conveyors Gate in intial state

© Festo Didactic GmbH & Co.KG. • prolog-factory

131

Process description

8.7.2

MES mode of Separating Station

In MES mode the Separating Station asks the server about the next order. If the coming workpiece has the same color than the order, the station transports it to the Robot Station with the separator gate. If the color of the workpiece is not correct, it will be transported to the Sorting Station. Sequence of separation in MES mode





After a workpiece arrives the station waits for 2 sec [spWait2s]. (It waits for the Storing Station.) Then switches the main conveyor motor on [spConv1On]. After the workpiece arrives to check point it waits for 1 sec [spWait1s]. Then the station asks for an order (M100.1) [spAskForOrder]. If it gets a task, it sends a “Task Started” message (M100.10) [spSendStarted]. Then it checks the color and material [spCheck].



If the color, material of the workpiece and the order are same:

   

o

Extends the separator gate, switches the perpendicular conveyor on, and registrates that the workpiece was good [spExtGate].

If the color, material of the workpiece and the order are different: o       

132

Registrates that the workpiece was not good [spNotOk].

Then the station waits for the next station [spWaitNext]. After the next station is free, the station retracts the stopper [spRetrStop]. After the workpiece arrives at the end of either of conveyor, the station waits for 2 sec [spWait2s_2]. 2 sec later it retracts the separator, extracts the stopper and stops the conveyors [spStop]. If the workpiece was good, the station inserts the workpiece into the buffer (M100.36) of the Robot Station [spInsertFIFO]. According to the type of the workpiece, the station sends a “Task Finished” message (M101.1) with or without error [spSendFinished]. After that the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

2

1

spIdle spWaitNext

Station on Idle state

Wait until next station is free

Station in MES mode, and workpiece arrives

Wait for sorting or for the robot buffer.

Next station is free

spWait2s

spRetrStop

Empty: Wait 2 sec

Retract the stopper 2 sec later Workpiece arrived to the end of either of conveyor

spConv1On

spWait2s_2

Switch the main conveyor on

Empty: Wait 2 sec Workpiece at check position 2 sec later

spWait1s

spStop

Empty: Wait 1 sec

Retr. Gate, ext. Stopper, stop conveyors 1 sec later Gate in intial state

spAskForOrder

spInsertFIFO

Entry: Send "Ask For a Task" (M100.1)

Entry: Insert wp. In rob. FIFO (M100.36)

If the workpiece was good

Answer received Answer received

spSendStarted Entry: Send "Task Started" (M100.10)

spSendFinished

If there is a task for the station.

Entry: Send "Task Finished" (M101.1)

If there was a task. Accorindg to the workpiece type, with or without error.

Answer received Answer received

spCheck Check and reg. the type of the workpiece

Workpiece is good

Else

spExtGate

spNotOk

Extend the separator and switch conv. 2 on

Reg. that the workpiece was not good

Registrate the workpiece type

Separator is not retracted

2

© Festo Didactic GmbH & Co.KG. • prolog-factory

1

133

Process description

8.8

Sorting Station

8.8.1

Standalone mode of Sorting Station

In standalone mode the Sorting Station sorts out the different types of workpieces to different slides. The Sorting Station does the same in MES mode. Sequence of sorting

      

134

If a workpiece arrives the station switches the conveyor motor on and waits for 2 sec [spConvOn]. Then checks the color and the material with an inductive-, and an optical sensor. According to the material and color, the station extends a separator or not [spExtRed / spExtBlack / spExtSilver]. Then retracts the stopper [spRetrStoper]. Waits for the falling edge of the sensor at the slides (-B4) [spWaitNotB4]. Retracts the separator (if it was extended), and extends the stopper [spStop]. If all separators are retracted, the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

spIdle Station on Idle state

Workpiece arrives

spConveyorOn Switch the conveyor motor on

Workpiece is red

Workpiece is black

Workpiece is silver

spExtRed

spExtBlack

spExtSilver

Extend the first separator

Extend the second separator

Do not extend any separator

First separator is extended

Second separator is extended

spRetrStoper Retract the stopper The sensor at the slide is on

spWaitNotB4 Empty: Wait until sensor is off at slide The sensor at the slide is off

spStop Retr. Sep., ext. Stopper switch conveyor off Separators are retracted

© Festo Didactic GmbH & Co.KG. • prolog-factory

135

Process description

8.9

Robot Station and Robotinos

8.9.1

Standalone mode of Robot Station and Robotinos

In standalone mode the Robot Station and the Robotinos work only in a simple sequence (in an infinite loop). The Robotino 1 moves an empty pallet from the input slide to the Robot Station. The Robot moves it to the next pallet place, and then commissioned it with for workpieces. The Robot moves the commissioned pallet to the output slide. The Robotino 1 transports it to the next position of the stock, and moves back to the output slide of the Robot Station. After that the Robotino 2 removes the pallet from the stock, and transports it to the next outline. Then the Robot Station starts the cycle again. Between the cycles the Robot Station and Robotinos switch to the next pallet position, stock position, and outline one after the other. In this case all positions will be tested in standalone mode. There is only one pallet in the system in the same time. The operator should remove manually the delivered pallet from the outline, and place a new empty pallet on the input slide. Sequence of robot station and robotinos

  

First the station initializes the variables [1]. Then it waits for an empty pallet on input slide [10]. The station sends the Robotino 1 to move the empty pallet to Robot Station [15].



If there is an error with the communication between Robotino 1 and the PLC: o



And waits until the Robotino 1 transports the empty pallet to the Robot station [20].



If there is an error with the communication between Robotino 1 and the PLC: o

   

The station jumps back to Idle state [10].



Then it waits until the workpiece arrives at the end of input slide [100]. The Robot moves the pallet to the next empty pallet place [105]. And waits until a workpiece arrives at conveyor belt [110]. Then the Robot moves the workpiece to the next free place of the pallet [115]. And calculates the next workpiece position [120].



If there is still a free place on the pallet: o

     

136

The station jumps back to Idle state [10].

The station jumps back to insert a new workpiece [100].

Then the station waits until output slide of the Robot is free [125]. After that it lifts up the pallet stopper [130]. And the Robot moves the commissioned pallet to the output slides [135]. Then waits until the Robot finishes the task [140]. After that the station writes the RFID data into the pallet [145]. And waits until the writing is finished [150].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

     

Then it lifts down the pallet stopper [155]. And waits until the pallet arrives at the bottom of output slide [160]. Then calculates the next pallet place [165]. The station switches between the pallet position one after the other to check all positions. If all pallet places have been already used, starts with the first place again [170]. Then the station sends the commissioned pallet to the stock with Robotino 1 [175]. If there is an error with the communication between Robotino 1 and the PLC: o

The station jumps back to sending the task to Robotino 1 [175].



And waits until Robotino 1 finishes the task, and arrives back to Robot Station [180].



If there is an error with the communication between Robotino 1 and the PLC: o

  

The station jumps back to sending the task to Robotino 1 [175].

After the Robotino 1 finishes the task, the station calculates the outline position [185]. If Robotino 2 is ready, Robotino 2 moves the pallet from the stock to the outline [190]. If there is an error with the communication between Robotino 2 and the PLC: o

The station jumps back to sending the task to Robotino 2 [185].



And waits until Robotino 2 finishes the task, and arrives back to Robot Station [195].



If there is an error with the communication between Robotino 2 and the PLC: o

    

The station jumps back to sending the task to Robotino 2 [185].

After the Robotino 2 finishes the task, the station calculates the outline position [200]. After the pallet arrives at the bottom of the outline slide (RFID tag is detected), the station reads out the RFID data from the pallet [205]. And then the station calculates the next storage and output position [250]. The station switches between the storage, and output positions one after the other to check all positions. If all storage positions, or all outlines have been already used, start again with the first storage position or outline [255]. Then jump back to Idle state [10] from an empty step [300].

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137

Process description

2

1

1 140

Initalize variables

Wait until robot task finished Robot finished the task

10

145

Wait for Auto Mode

Write RFID data into pallet

Station in standalone mode, and buffer and storage are empty

15

150

Send Robotino 1 for an empty pallet

Wait RFID write finished RFID write finished

Robotino 1 is busy (started the task)

Error in Robotino 1 communication

155

20

Lift down the pallet stopper

Empty: Wait until Robotino 1 finished

Robotino 1 is ready

160

Error in Robotino 1 communication

Wait until pallet at slide end

100 Wait for empty pallet on Robot slide

Pallett stopper in lower position and pallett at slide end

165

Empty pallet is on Robot's input slide

Switch to the next pallet position

105 Move the empty pallet to next pallet position

The next pallet position is stored in byPalPos

170

Robot finished the task

If next pos. > 4 change to pal. Pos 1

110 Empty: Wait for workpiece at conveyor

Next storage position is free, and Robotino 1 is ready

175

Workpiece available at conveyor belt

Send pallet to the stock with Robotino 1

115 Move workpiece to the next position on pall.

The next position on pallet is stored in byPalIndex

After that the Robotino 1 will go back to Robot Station

Robotino 1 is busy (started the task)

Robot finished the task

180

120

Empty: Wait until Robotino 1 finished

Switch to the next position on pallet.

Robotino 1 is ready The index is 1 again

Error in Robotino 1 communication

Else

Error in Robotino 1 communication

125 Empty: Wait for Robot outslide is free

185

Robot's output slide is free

Calculate the outline position

130 Lift up the pallett stopper

Robotino 2 is ready

190

Pallett stopper in upper position

move pall. to outline with Robotino 2

135 Move the pallet to output slide

2

Robotino 2 is busy (started the task)

1 5

138

Error in Robotino 2 communication

3

4

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

© Festo Didactic GmbH & Co.KG. • prolog-factory

139

Process description

8.9.2

MES mode of Robot Station

In MES mode there are three tasks (empty tray insertion, commissioning and delivery of commissioned pallet). The station tries to avoid serving the same task twice in a row. The empty tray insertion has the highest priority, then the commissioning, and the delivery. The first task is inserting the incoming empty pallet to a free pallet place. If there is an empty pallet on input slide, and there is a free pallet place, the station moves the pallet to the free place, and registrates the insertion in MES server. The second task is the commissioning. If there is a pallet on a pallet place, a workpiece on the conveyor, and the last insertion was more than 1s before, the Robot asks for an insertion task form MES, and moves the workpiece to the specific place. The third task is the delivery of commissioned pallet. If there is a pallet at a pallet place, the output slide is free, and the last delivery was more than 1s before, the Robot ask for a delivery task from MES, and it moves the specific pallet to the output slide. Sequence of empty pallet insertion



If there is an empty pallet on the input slide, and there is a free pallet place, the station searches for the next free pallet place [100].



If there is no free place: o

     

140

The station jumps back to Idle state [10].

The Robot moves the pallet from the input slide to the specific pallet place [110]. Waits until the Robot finishes the task [115]. After the Robot finishes, the station checks the return code from the Robot [116]. After the return code is 0 the station books the pallet in pallet buffer of MES server (M100.31) [120]. Then the station waits for the answer from MES [125]. After that the station will be on Idle state [10].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

10 Station on Idle state MES mode is active, there is an empty pallet on input slide, and one of the pallet places is free

100 Search for the next free pallet place

There is a free place

Else

110 Move the pallet from the input to the place

115 Wait until Roboto finishes the task Robot finished the task

116 Check robot return code Return code = 0

120 book pallet on MES pall. buffer (M100.31)

125 Empty: Wait MES request finished Answer received

© Festo Didactic GmbH & Co.KG. • prolog-factory

141

Process description

Sequence of commissioning a pallet

  

If there is a workpiece on the conveyor belt, there is a pallet on a pallet place, and the last workpiece insertion was more than 1s before, the station registrates the start of commissioning [200]. Then it asks for a commissioning task from MES (M100.2) [205]. And waits for the answer [210].



If there is no task for commissioning: o

 

The station asks the MES, where to place the workpiece (M101.35) [215]. And waits for the answer [220].



If there is no place for insertion: o

         

142

The station jumps back to Idle state [10].

The station jumps back to Idle state [10].

The station sends a “Task started” message (M100.10) to the MES [225]. And waits for the answer [230]. Then the station moves the workpiece to the pallet [250]. And waits until the Robot finishes the task [255]. Checks the return code from the Robot [256]. After the return code is 0, the station removes the workpiece from the FIFO of MES server (M100.37) [260]. And waits for the answer from MES [265]. Then the station sends a “Task finished” message (M101.1) [270]. And waits for the answer [275]. After the answer received, the station will be on Idle state [10].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

2

1

10 230

Station on Idle state MES mode is active, there is a workpiece on conveyor, other is a pallet, and last workpiece insertion was more than 1 sec before.

Empty: Wait MES request finished Answer received

200

250

Registrate the start of insertion

Move the workpiece to the pallet

205

255

Check if order in MES available (M100.2)

Empty: Wait until robot finish Robot finished the task

210

256

Empty: Wait MES request finished

Check Robot return code

Answer received There is a task for Insertion

Return code = 0

Else

260 Remove workpiece from FIFO (M100.37)

215 Ask MES, where to place wp. (M101.35)

265 Empty: Wait MES request finished

220 Empty: Wait MES request finished

Answer received

270

Answer received There is a place for insertion

Send "Task Finished" (M101.1) Else

225 Send "Task Started" (M100.10)

2

© Festo Didactic GmbH & Co.KG. • prolog-factory

1

275 Empty: Wait MES request finished Answer received

143

Process description

Sequence of delivering the commissioned pallet

  

If there is a pallet on a pallet place, the output slide is free, and the last delivery was more than 1s before, the station registrates the start of delivery [300]. Asks for a delivery task from MES (M100.2) [305]. And waits for the answer [310].



If there is no task for delivery: o

                 

144

The station jumps back to Idle state [10].

The station asks the MES, which pallet should be delivered (M100.30) [315]. And waits for the answer [320]. The station sends a “Task started” message (M100.10) to the MES [325]. And waits for the answer [330]. Then it lifts up the pallet stopper [345]. And waits until the stopper reaches the upper position [350]. If the stopper is in upper position, the Robot moves the pallet to the output slide [355]. Then the station waits until the Robot finishes the task [360]. After that it checks the return code from the Robot, and waits until it is 0 [361]. The station writes the RFID data into the pallet [365]. And waits until the writing is finished [370]. Then lifts down the pallet stopper [375]. And waits until the pallet reaches the bottom end position of the output slide [380]. Then the station updates the buffer position (removes the delivered pallet) in MES (M100.31) [390]. And waits for the answer [395]. Then it sends a “Task finished” message (M101.1) to the MES [400]. And waits for the answer [405]. After the answer received, the station will be on Idle state [10].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

2

1

10 355

Station on Idle state MES mode is active, there is a pallet on pall. place, output slide is free, and last delivery was more than 1 sec before.

Move commissioned pallet to out slide

300

360

Registrate the start of delivery

Empty: Wait until robot finishes

Robot finished the task

Robot finished the task

305

361

Check if order in MES available (M100.2)

Check Robot return code Return code = 0

310

365

Empty: Wait MES request finished

Write RFID datat into pallet

Answer received

Ther is a task

Else

370 Wait RFID write finished

315 Search for the pallet to move (M100.30)

RFID write finished

375 Lift down pallet stopper

320 Empty: Wait MES request finished Answer received

380 Wait until pallet at slide end

325 Send "Task started" (M100.10)

Pallett stopper in lower position and pallett at slide end

390 Update buffer in MES (M100.31)

330 Empty: Wait MES request finished Answer received

395 Empty: Wait MES request finished

345 Lift up pallet stopper

Answer received

400 Send "Task fininshed" (M101.1)

350 Wait pallet stopper in upper end position Pallet stopper in upper position

2

1

Pallet stopper in upper position

405 Empty: Wait MES request finished Answer received

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Process description

8.9.3

MES mode of Robotino 1

In MES mode there are two tasks for Robotino 1 (commissioned pallet transportation from Robot Station to Robotino Storage, empty tray transportation to Robot Station). The commissioned pallet transportation has a higher priority. If a pallet is on the output slide of Robot Station, the Robotino asks the MES about next task. If there is a task, the Robotino transports the pallet to a free storage position, and registrates it in MES. After that the Robotino moves back to Robot Station. If an empty pallet is available on the input slide, and the input slide of the Robot Station is free, the Robotino moves the empty pallet to the Robot Station. In this case the Robotino does not have any communication with the MES server. Sequence of commissioned pallet transportation to storage

 

If a pallet is on the output slide of Robot Station, the Robotino asks the MES about next task (M100.2) [200]. And waits until the answer received from MES [210].



If there is no task: o

    

Then the PLC searches for a free place in Robotino Storage [215]. Sends a “Task started” message (M100.10) to MES [220]. And waits until the answer received from MES [225]. Then the Robotino moves the commissioned pallet from the Robot Station to the Robotino Storage [230]. And waits until the Robotino is busy [235].



If there is a communication error between Robotino and PLC: o

The station jumps back to send the task again [230].



Then the station waits until Robotino finishes [240].



If there is a communication error between Robotino and PLC: o

    

146

The station jumps back to Idle state [10].

The station jumps back to send the task again [230].

Then the PLC books the Robotino Storage position in MES server (M100.31) [245]. And waits until the answer received from MES [250]. Then sends a “Task finished” message (M101.1) to MES [255]. And waits until the answer received from MES [260]. Then the Robotino will be on Idle state.

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

2

1

10 Station on Idle state MES mode is active, there is a pallet on output slide at Robot Station, and there is a free place in the storage

230 Robotino moves the pallet to sock.

200 Ask for a task from MES (M100.2)

235 Empty: Wait until Robotino is busy

210 Empty: Wait MES request finished

Robotino is busy

Error in Robotino communication

240

Answer received

Empty: Wait until Robotino finished Ther is a task

Else

215

Robotino finished

Find next free shelf in storage Free place found

Error in Robotino communication

245 Book pallet on MES stock buffer (M100.31)

220

Free place found

Send "Task started" (M100.10)

250 Empty: Wait MES request finished

225

Answer received

Empty: Wait MES request finished Answer received

2

255 Send "Task finished" (M101.1)

1

Free place found

260 Empty: Wait MES request finished Answer received

© Festo Didactic GmbH & Co.KG. • prolog-factory

147

Process description

Sequence of empty pallet transportation to the Robot Station

 

If an empty pallet is available on the input slide, and the input slide of the Robot Station is free, the Robotino moves the empty pallet to the Robot Station [100]. And the PLC waits until the Robotino is busy [105].



If there is a communication error between Robotino and PLC: o

The PLC jumps back to send the task again [100].



Then the PLC waits until the Robotino is finished [110].



If there is a communication error between Robotino and PLC: o



The PLC jumps back to send the task again [100].

After the Robotino finishes, the station will be on Idle state [10].

10 Station on Idle state MES mode is active, there is a pallet on input slide, and the input slide of Robot Station is free

100 Robotino moves empty pallet to Robot

105 Empty: Wait until Robotino is busy

Robotino is busy

Error in Robotino communication

110 Empty: Wait until Robotino finished

Robotino finished

148

Error in Robotino communication

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

8.9.4

MES mode of Robotino 2

In MES mode the Robotino 2 has only one task (Transportation of commissioned pallet from Robotino Storage to outline slide). Before the delivery the PLC asks the MES server about the destination of the pallet. If the destination is not defined, the PLC selects the next free output slide. Sequence of pallet delivery to output slides

 

If there is a free output slide, and a pallet in the Robotino Storage, the Robotino asks for parameters of pallet delivery (M100.41) [100]. And waits for the answer from MES [110].



If there is no task for delivery: o



The station jumps back to Idle state [10].



After that the Robotino selects the destination slide. If there is a predefined slide, the Robotino selects that. If there is not a predefined slide, the Robotino selects the first free output slide from the left [115]. Then the PLC sends a “Task started” message (M100.10) to the MES [120]. And waits for the answer from MES [125]. The Robotino transports the pallet form the storage to the selected output slide [130]. And the PLC waits until Robotino is busy [135].



If there is a communication error between Robotino and PLC:

  

o

The PLC jumps back to send the task again [130].



Then the PLC waits until Robotino finishes the task [140].



If there is a communication error between Robotino and PLC: o

    

The PLC jumps back to send the task again [130].

The PLC updates the Robotino Storage buffer in MES (M100.31) [145]. And waits for the answer from MES [150]. Then the PLC sends “Task finished” message (M100.31) to MES [155]. And waits for the answer from MES [160]. After the answer is received, the station will be on Idle state [10].

© Festo Didactic GmbH & Co.KG. • prolog-factory

149

Process description

2

1

10 150

Station on Idle state MES mode is active, there is a free output slide, there is a pallet in the Robotino storage

Empty: Wait MES request finished Answer received

100 155

Get parameters for delivery (M100.41)

Send "Task finished" (M101.1)

110 160

Empty: Wait MES request finished

Empty: Wait MES request finished

Answer received Answer received There is a delivery task from storage

Else

115 Select output slide

120 Send "Task started" (M100.10)

125 Empty: Wait MES request finished Answer received

130 Robotinio moves the pallett to out. slide

135 Empty: Wait until Robotino is busy

Robotino is busy

Error in Robotino communication

140 Empty: Wait until Robotino finished

Robotino finished

Error in Robotino communication

145 Update storage buffer in MES (M100.31)

2

150

1

© Festo Didactic GmbH & Co.KG. • prolog-factory

9

Technology

This chapter refers to the technology of the system. The conveyor belt, with a width of 40 mm, is driven by 24 V-engines, which results in an average transport speed of about 9 m/min. For better construction understanding of the station, the technical drawings should be a very helpful data. The rooms must be checked for their technical datas before built up the station/system. The size of the door openings and the entrance must be big enough for the measurements of the system. Even the load-capacity of the floor must be high enough for the system. 9.1

drawings

Technical drawing

© Festo Didactic GmbH & Co.KG. • prolog-factory

151

Technology

9.2

Modules in use

The conveyor system is made up of a number of different function modules, some of which are also used in the field of MPS-Plus. Pallet Work pieces

9.2.1

Pallet

Responsible for the transport of 4 processed or unprocessed cylinders. The palette can be moved from the robot by means of the reception aid at the center of the palette. On the bottom side there is the RFID Sensor. Measurements: 164 x 164 mm

Pallet 1BPW

152

© Festo Didactic GmbH & Co.KG. • prolog-factory

Technology

9.2.2

Work pieces

There are 3 different work pieces, they distinguish in their color – red, black and silver work pieces are available.

Work pieces

© Festo Didactic GmbH & Co.KG. • prolog-factory

153

Technology

154

© Festo Didactic GmbH & Co.KG. • prolog-factory

10 Pneumatic

10.1

Pneumatic supply

The pressure in the supply line must not exceed 10 bar. A fine filter has to be installed, to prevent contamination by rust or similar. A stop cock is required for the supply of the installation. The pressure regulators should be set in between 5 and 6 bar. The filter and water separators require maintenance according to the instructions of the documentation of these components. The exact allocation of the valve terminal can be found in the pneumatic plan.

Service unit

© Festo Didactic GmbH & Co.KG. • prolog-factory

155

Pneumatic

156

© Festo Didactic GmbH & Co.KG. • prolog-factory

11 Electrical system

To operate the system it is required to connect all of the supply cables and communication lines included. The cables used to program the system are explained additionally. To give you a better survey of the being lines used in the plant, these are explained in the following. 11.1

Power supply

The devices are delivered together with the respective power supply plugs, protectively contact covered, in case they require power supply. The customer must ensure that the power supply is earthed correctly and is equipped with a fault current monitor. If it is required for several devices to be in operation at the same time, it is possible to connect these to a switchboard containing distribution board, provided that the permissible maximum rating is not exceeded. Each station contains its own individual EMERGENCY STOP switch, which at first reacts to its respective station only. It has to be clarified in advance, if a central ROOM EMERGENCY STOP switch is required.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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Electrical system

11.2

Controller

The controller of the log area is located at the profile rack of the table. No.

Name

Comment

1

BL20-GW-DPV1

Controller

2+3

BL20-2RFID-S

Card for RFID sensors

4

24V Power

Card for powers supply inputs

5-10

BL20-4DI-24VDC-P

Cards for digital Inputs

11

24V Power

Card for powers supply outputs

12-14

BL20-4DO-24VDC-0,5A-P

Cards for digital outputs

S7 controller transport system example

158

© Festo Didactic GmbH & Co.KG. • prolog-factory

Electrical system

11.3

Wiring

The wiring within the station and the wiring to the other stations are explained in the following. 11.3.1 I/O-Components The operating strip, the moduls from the profil plate and the z-axis are pluggable connected via I/O-terminals to the SM323 I/O-cards from the control. So that a perfect communication can be ensured, the I/O interface is standardized. The I/O terminal is at all work positions at the disposal.

I/O-Terminal

Technical data

© Festo Didactic GmbH & Co.KG. • prolog-factory

Plug type

IEEE 488 24 pins

Inputs

8

Outputs

8

Current consumption

Max. 1A/PIN

Power supply

24 VDC

159

Electrical system

Allocation I/O- Terminal

Clamp

Bit

Function

Colour

Clamp

Bit

Function

Colour

01

0

Output

White

13

0

Input

Grey-pink

02

1

Output

Brown

14

1

Input

Red-blue

03

2

Output

Green

15

2

Input

White-green

04

3

Output

Yellow

16

3

Input

Brown-green

05

4

Output

Grey

17

4

Input

White-yellow

06

5

Output

Pink

18

5

Input

Yellow-brown

07

6

Output

Blue

19

6

Input

White-grey

08

7

Output

Red

20

7

Input

Grey-brown

24V

Power supply

Black

21

24V

Power supply

White-pink

09

10 11

12

160

22 0V

Power supply

Pink-brown

23

0V

Power supply

purple

24

0V

Power supply

White-blue

© Festo Didactic GmbH & Co.KG. • prolog-factory