Manual CIROS® Advaned Mechatronics EN - Festo Didactic

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Manual CIROS® Advaned Mechatronics EN - Festo Didactic

CIROS ®

Advanced

Mechatronics

Manual

572761 EN

01/2010


2

Order No.: 572761

Status: 01/2010

Authors: Christine Löffler

Graphics: Doris Schwarzenberger

Layout: 01/2010, Beatrice Huber, Julia Saßenscheidt

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, 2006-2010

Internet: www.festo-didactic.com

E-Mail: did@de.festo.com

The copying, distribution and utilisation of this document as well as the

communication of its contents to others without express authorisation

is prohibited. Offenders will be held liable for the payment of damages.

All rights reserved, in particular the right to carry out patent, utility

model or ornamental design registration.


Contents

1. What will you learn from the manual? ____________________ 5

2. This is how you install CIROS ® Advanced Mechatronics _____ 8

2.1 User-specific installation of default sample systems

and S7 programs used ________________________________ 8

3. The CIROS ® Advanced Mechatronics system _____________ 11

3.1 Summary of CIROS ® Advanced Mechatronics _____________ 11

3.2 A distributed system in CIROS ® Advanced Mechatronics ____ 15

3.3 Communication in distributed systems __________________ 17

3.4 The preassembled station models in

CIROS ® Advanced Mechatronics _______________________ 19

3.5 Controlling a station with internal PLC __________________ 27

3.6 Controlling a station with external PLC __________________ 28

3.7 Functions for setting faults in a system __________________ 30

3.8 Functions for analysing a system ______________________ 31

3.9 Directory and file structure of

CIROS ® Advanced Mechatronics _______________________ 33

4. Main control functions of CIROS ® Advanced Mechatronics __ 38

4.1 Creating a new MPS ® Standard system

from preassembled station models _____________________ 38

4.2 Creating an MPS ® 500-FMS system

from preassembled station models _____________________ 58

4.3 Modifying an existing system _________________________ 78

4.4 Creating and monitoring communications links

in a system ________________________________________ 93

4.5 Simulating a system ________________________________ 120

4.6 Operating and monitoring a system ___________________ 124

4.7 Changing the view of a system _______________________ 145

4.8 The Inputs and Outputs windows _____________________ 149

4.9 The Manual Operation window _______________________ 157

4.10 Controlling a system using the internal S7 PLC __________ 183

4.11 Controlling a system station using

the external Soft PLC S7-PLCSIM ______________________ 199

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Contents

4.12 Controlling a station of the system using

the external Soft PLC CoDeSys SP PLCWinNT ____________ 215

4.13 Controlling a station of the system using an external PLC __ 241

4.14 Setting faults in a system ____________________________ 259

4.15 Eliminating faults in a system ________________________ 267

4.16 Logging error elimination ____________________________ 272

5. These training contents can be taught using

CIROS ® Advanced Mechatronics ______________________ 274

5.1 Training contents and training aims ___________________ 274

5.2 Target group ______________________________________ 277

5.3 Prior knowledge ___________________________________ 277

5.4 Example: Allocation of training aims to syllabi ___________ 278

5.5 The training concept of CIROS ® Advanced Mechatronics ___ 284

5.6 Training scenarios for CIROS ® Advanced Mechatronics ____ 286

6. This is how you create and operate a distributed

system in CIROS ® Advanced Mechatronics ______________ 289

6.1 Training aims _____________________________________ 289

6.2 Support via CIROS ® Advanced Mechatronics ____________ 290

6.3 Example: Configuration of a distributed system from

MPS ® Standard stations and simulating production ______ 290

7. This is how you analyse information flow in

a distributed system ________________________________ 318

7.1 Training aims _____________________________________ 319

7.2 Methods _________________________________________ 319

7.3 Support via CIROS ® Advanced Mechatronics ____________ 321

7.4 Example: Analysing information flow in

a distributed MPS ® Standard system __________________ 321

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1. What will you learn from the manual?

What is CIROS ® Advanced

Mechatronics?

CIROS ® Advanced Mechatronics is an application from the CIROS ®

Automation Suite.

CIROS ® Advanced Mechatronics is a PC based graphic 3D simulation

system for distributed automation systems. These systems consist of

different, internetworked, intelligent stations. The distributed systems

represent automation processes of varying complexity.

In the documentation and software, these systems are also referred to

as process models or workcells.

CIROS ® Advanced Mechatronics is a tool whereby you

define an automation process and configure the corresponding

system for the predefined stations,

familiarise yourself with the mode of operation of a system,

familiarise yourself with and plan the communication between the

networked stations of a distributed system,

practise PLC programming and testing of PLC programs with the help

of systems,

carry out systematic fault finding on a system.

The individual contents can be extended in complexity depending on

the trainees’ prior knowledge.

The simulated systems are also available as actual systems. With these

you can successfully apply and consolidate the knowledge gained on

the virtual automation systems using actual systems.

In addition to the ready-made process models, CIROS ® Advanced

Mechatronics also offers you the option of simulating process models of

your own design. You can create and modify process models using

CIROS ® Professional, which is a further application available from the

CIROS ® Automation Suite.

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1. What will you learn from the manual?

Target group

Structure of the manual

Conventions

Notation Meaning

The manual is intended for

Trainers and teachers

The manual provides them with ideas and suggestions as to how

CIROS ® Advanced Mechatronics can be used in lessons and in

vocations and further training.

Trainees and students

For whom the information and instructions on how to operate

CIROS ® Advanced Mechatronics are of particular interest.

The manual is divided into the following subject areas:

Chapter 2 contains information and instructions regarding the

installation and licencing of CIROS ® Advanced Mechatronics.

Chapters 3 and 4 describe the system and the main operational

functions of CIROS ® Advanced Mechatronics.

Chapter 5 deals with the didactic aspects and lists the training

contents taught with CIROS ® Advanced Mechatronics. It further

represents the training concept and the resulting possibilities for

use in lessons.

Chapters 6 and 7 describe actual problems in relation to the training

contents, methodological procedures towards solutions and

implementation in CIROS ® Advanced Mechatronics.

Specific notation is used for texts and key combinations and key

sequences to help you find information more easily.

Bold This format is used for command names, menu names, dialog box names,

directory names and command options.

Key1+key2 A plus symbol (+) between the key names means that the keys quoted must

be pressed simultaneously.

Key1‟key2 A minus symbol (-) between the key names means that the keys quoted must

be pressed in sequence.

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1. What will you learn from the manual?

Additional support

Further descriptions and support is available via the online Help. The

online Help consists of:

CIROS ® Help for operation and

CIROS ® Advanced Mechatronics Assistant.

CIROS ® Help contains detailed information regarding the functions and

operation of CIROS ® Advanced Mechatronics.

CIROS ® Help is a component part of the CIROS ® Automation Suite and

describes the functionality of various, different CIROS ® applications.

The functional scope of CIROS ® Help is therefore greater than that

required for CIROS ® Advanced Mechatronics.

The menu of the online Help provides functions that you are already

familiar with from a standard Internet browser. These include: Next and

Back, Select Home Page, Print Selected Topics, Show/Hide the

Navigation bar or Set Options for Internet Connection.

Moreover, via extension registers such as Content, Search, Favourites,

you also have the option of conveniently navigating through the

information in CIROS ® Advanced Mechatronics Help.

The CIROS ® Advanced Mechatronics Assistant provides detailed

functional descriptions and technical documentation regarding the

individual stations. A sample PLC program is included for each station.

The PLC program is created in STEP 7.

Moverover, CIROS ® Advanced Mechatronics Assistant offers you direct

access to some ready made sample systems and prepared exercises.

A Getting Started section is also integrated for a quick introduction to

CIROS ® Advanced Mechatronics.

An Adobe Acrobat Reader must be installed on your PC to enable you to

view PDF documents. The Adobe Acrobat Reader program is available

free of charge and you can download this from the Internet address

www.adobe.de.

Our telephone hotline is available at any time, should you have any

queries during the installation or operation of CIROS ® Advanced

Mechatronics.

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2. This is how you install CIROS ® Advanced

Mechatronics

2.1

User-specific installation

of default sample systems

and S7 programs used

To install CIROS ® Advanced Mechatronics you will need the CIROS ®

Automation Suite DVD-ROM, where all the software packages of the

CIROS ® Automation Suite are ready for installation. It also includes the

manuals in the form of PDF documents for the individual software

packages.

On completion of the installation, you will need to execute the licencing.

As soon as this is successfully completed you can start CIROS ®

Advanced Mechatronics.

For further information regarding system requirements, installation and

licencing, please refer to the enclosed instructions.

To be able to simulate a modelled system, a PLC program must be

available for each station of the system in order to control the operation

of the station. Each station is equipped with an internal PLC to execute

PLC programs. A S7 simulator is used as internal PLC.

If you are working with the default settings of CIROS ® Advanced

Mechatronics, the prepared sample PLC program is automatically

downloaded to the internal PLC and executed once simulation is

started. This enables you to simulate the sample systems provided and

any newly created system straight away and without errors.

If you wish to modify one or several sample PLC programs, then the PLC

programs must be installed in an additional subdirectory specified by

you, where you can effect your changes. You can then download the

modified programs to the appropriate station of your system and

execute these. You can of course also download the modified PLC

programs to an external PLC, in which case the respective station of the

system using an external PLC.

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2. This is how you install CIROS ® Advanced Mechatronics

By using this procedure, the default PLC programs used

by CIROS ® Advanced Mechatronics remain unchanged and can be

downloaded again to the internal PLC of a station.

CIROS ® Advanced Mechatronics supports you in the user-specific

installation of the sample systems and S7 programms. To do so, open

up CIROS ® Advanced Mechatronics Assistant.

CIROS ® Advanced Mechatronics differentiates between reference

models und user models.

Reference models are sample systems which are filed in the

program directory of CIROS ® Advanced Mechatronics and are write

protected. The model and associated PLC programs cannot be

modified. This ensures that the process model can be opened and

correctly simulated at any time.

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2. This is how you install CIROS ® Advanced Mechatronics

User models, if created and opened with the help of CIROS ®

Advanced Mechatronics Assistant, are filed as standard in your

personal folder under own files\CIROS\CIROS Advanced

Mechatronics Samples. These are not write protected and you

therefore can for example modify the appropriate PLC programs and

replace these with your own. The program directory with the user

models represents your individual working environment for CIROS ®

Advanced Mechatronics.

You can also copy the user models into a folder other than into the

standard preset folder. You will find the information for this in CIROS ®

Advanced Mechatronics Assistant.

For the user modells created with the help of CIROS ® Advanced

Mechatronics Assistant the following directory structure is created:

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3. The CIROS ® Advanced Mechatronics system

3.1

Summary of CIROS ®

Advanced Mechatronics

The following form part of CIROS ® Advanced Mechatronics:

The simulation software CIROS ® Advanced Mechatronics,

The communication software EzOPC,

The online CIROS ® Advanced Mechatronics Help,

An online CIROS ® Advanced Mechatronics Assistant,

An Online Help for EzOPC,

A PDF document with information regarding the licencing and

installation of a licence server,

A manual in the form of a PDF document for the operation of CIROS ®

Advanced Mechatronics.

CIROS ® Advanced Mechatronics is a PC-based graphic 3D simulation

system which serves as an introduction to automation systems with

distributed intelligence.

CIROS Advanced Mechatronics enables you to create, program and

simulate distributed systems of varying complexity.

A distributed system consists of one or several stations. One station is

characterised by the fact that it independently executes specific

machine functions; it is therefore an autonomous system part with its

own PLC program.

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3. The CIROS ® Advanced Mechatronics system

Library

with

station

models

Easy

Port

External

PLC

CIROS ® Assistant

System consisting of station models

Station 1

Internal

S7 PLC

S7-PLCSIM

OPC-Client

EzOPC (OPC-Server)

Station 2

Internal

S7 PLC

Component parts of CIROS ® Advanced Mechatronics

Station 2

Internal

S7 PLC

CoDeSys PLCWinNT

CIROS ® Help

Control

functions

The following is required in order to simulate the operation of a

distributed system:

A graphic process model of the distributed system,

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...

A PLC program and PLC for each station, which autonomously

controls the operation of the station and, if required, exchanges

information with other stations,

A simulator that simulates the behaviour of the system. This

simulation ensures for example that cylinders move and sensors are

actuated.


3. The CIROS ® Advanced Mechatronics system

Each station is stored in a library together with a sample PLC program.

The PLC program defines a possible sequence of the station. You can of

course create new PLC programs, which generate a different process

sequence.

If a system is now modelled from the prepared stations, the

corresponding PLC program is automatically downloaded to the internal

PLC of the station. A SIMATIC S7 simulator is used as internal PLC,

which executes the PLC program once simulation is started.

In order to ensure that the stations of the system interact correctly, they

need to exchange information.

The default communication links used between the stations are

established automatically.

This facility enables you to simulate the operation of a system

immediately after modelling.

The advantage of this is that you can familiarise yourself with, operate

and observe the process without having to create the PLC programs for

the individual stations beforehand.

In the next step you can establish or change the communication links

yourself and make the necessary adjustments in the PLC programs.

One particular additional function provided by CIROS ® Advanced

Mechatronics is the possibility of fault simulation, whereby it is possibly

to set typical faults in the system. Possible causes of malfunction are for

example a mechanically misadjusted sensor, a cable break or failure of

a complete. The cause of the fault must be found by means of

systematic fault finding and eliminated.

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3. The CIROS ® Advanced Mechatronics system

Note

The monitoring and analysing of processes and the elimination of faults

is a focal point of CIROS ® Advanced Mechatronics.

A further focal point is the creation of your own PLC programs for

individual stations. These PLC programs are downloaded to an external

PLC and CIROS ® Advanced Mechatronics exchanges the input/output

signals with the external PLC via the OPC interface.

The following are possible as external PLC:

Any actual PLC,

The Soft-PLC SIMATIC S7-PLCSIM,

The soft PLC CoDeSys PLCWinNT.

CIROS ® Advanced Mechatronics requires the software program EzOPC

for the link to an external PLC. The OPC server EzOPC communicates

with any PLC via the EasyPort interface.

In addition to the ready-made process models, CIROS ® Advanced

Mechatronics also offers you the option of using process models of your

own design. You can create and modify process models using CIROS ®

Professional, which is a further application available from the CIROS ®

Automation Suite.

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3. The CIROS ® Advanced Mechatronics system

3.2

A distributed system in

CIROS ® Advanced

Mechatronics

Systems can be created from one or several stations. Each station

represents an "intelligent unit", which independently executes specific

machine functions.

An "intelligent unit" consists of a station, a predefined sequence with

predefined communication interface, a PLC program, an internal PLC

and an optional robot program. The predefined sequence of the PLC

controlled stations can of course be modified by the user.

All stations are prepared for your use:

Processing station,

Fluidic Muscle Press station,

Handling station

Automated warehouse station,

Storing station,

Pick & Place station,

Testing station,

Buffer station,

Quality assurance station,

Robot station,

Robot assembly station,

Sorting station,

Separating station,

Pallet transport system with 6 working positions ‟ so-called docking

positions - for MPS ® 500-FMS stations,

Distributing station.

Two types of system can be created from the stations listed above:

MPS ® Standard systems,

MPS ® 500-FMS systems.

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3. The CIROS ® Advanced Mechatronics system

Example of an MPS ® Standard system

Example of an MPS ® 500-FMS system

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3. The CIROS ® Advanced Mechatronics system

Note

3.3

Communication in

distributed systems

The stations are available from two libraries:

The MPS ® stations library,

the MPS ® 500-FMS library.

Due to the technological functions of the individual stations and if using

the prepared PLC programs, only specific combinations are permissible

when modelling a system.

A system can also be configured of only one station. This enables you to

teach all the training contents for which only one individual station is

required.

MPS ® systems perform different production processes:

MPS ® Standard systems perform the assembly of measuring

instruments and short-stroke cylinders.

MPS ® 500-FMS systems include stock administration and assembly

of short-stroke cylinders.

To ensure the correct sequence of the production process, the

"intelligent units" of the system must exchange information. In other

words, they need to communicate with one another. In MPS ® systems

these are the individual stations. How and with whom the stations

communicate depends on their position in the material flow.

In the case of MPS ® Standard systems a station usually communicates

with the preceding and successor station. In the standard version, one

bit is exchanged in each case. Information is exchanged via optical

sensors. This type of coupling of stations is referred to as StationLink.

Through-beam senor emitters and receivers are used as StationLink

sensors.

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3. The CIROS ® Advanced Mechatronics system

With MPS ® 500-FMS systems, each station forming part of the

transport system communicates with the transport system. Only in this

way does the transport system know which stations are involved in the

production process and in which working position these are.

If two stations are in use at one working position, such as the

distributing and testing stations at the position for incoming goods, an

information exchange therefore also takes place between these two

stations.

Projection and representation of communication links

All stations of an MPS ® 500-FMS system communicate via the coupling

of PLC inputs and outputs. This type of communication is known as I/O

connection. In addition, the stations located at the working positions of

the transport system use the optical sensors for information exchange.

The part of communication conducted via I/O connection can be

graphically projected and modified.

If changes are made in the communication link, you need to make sure

that the PLC programs of the respective stations make available the

communication information accordingly and conversely also evaluate it

again.

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3. The CIROS ® Advanced Mechatronics system

3.4

The preassembled station

models in CIROS ®

Advanced Mechatronics

Station model Description

The station models are realistic replications of existing stations.

Apart from the graphic representation, each station model comes with a

sample PLC program and, if required, a robot program.

Processing station

This model is a simulation of the MPS ® processing station

from Festo Didactic. On this station workpieces are to be

tested, processed and transferred to the neighbouring

station.

Fluidic Muscle Press station

This model is a simulation of the Fluidic Muscle Press

station from Festo Didactic. On this station workpiece

inserts are to be pressed into the workpiece housings and

the finished workpiece transported to the transfer position.

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3. The CIROS ® Advanced Mechatronics system

Station model Description

Handling station

This model is a simulation of the MPS ® handling station

from Festo Didactic. On this station workpieces are to be

removed from a mounting and, depending on the result of

the material testing, deposited on a slide. The workpieces

can also be passed on to a neighbouring station.

Automated warehouse station

This model is a simulation of the automated warehouse

station of Festo Didactic. On this station workpiece are to

be stocked up and taken out.

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3. The CIROS ® Advanced Mechatronics system

Station model Description

Storing station

This model is a simulation of the storing station of Festo

Didactic. Depending on the position of the station within

the material flow, workpieces are to be either stocked up or

taken out.

Pick & Place station

This model is a simulation of the Pick & Place station of

Festo Didactic. On this station workpieces are to be placed

onto workpiece housings and the complete workpiece is

transported to the transfer station.

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3. The CIROS ® Advanced Mechatronics system

Station model Description

Testing station

This model is a simulation of the MPS ® testing station from

Festo Didactic. On this station the material condition of the

workpieces is to be established and the workpiece height

checked. Depending on the test result, the workpiece is to

be ejected or transferred to the neighbouring station.

Buffer station

This model is a simulation of the MPS ® testing station from

Festo Didactic. On this station workpieces are to be

transported, buffered and separated.

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3. The CIROS ® Advanced Mechatronics system

Station model Description

Quality assurance station

This model is a simulation of the MPS ® quality assurance

station from Festo Didactic. On this station the shape

tolerance of workpieces is to be tested.

Robot station

This model is a simulation of the MPS ® robot station from

Festo Didactic. On this station workpieces are to be sorted

according to colour and the correct alignment of

workpieces monitored. Depending on the result,

workpieces are sorted into different magazines and passed

on to the neighbouring station.

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3. The CIROS ® Advanced Mechatronics system

Station model Description

Robot assembly station

This model is a simulation of the MPS ® robot assembly

station from Festo Didactic. On this station a model

cylinder is to be assembled from a basic body.

Sorting station

This model is a simulation of the MPS ® sorting station from

Festo Didactic. On this station workpieces are to be sorted

according to material and colour.

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3. The CIROS ® Advanced Mechatronics system

Station model Description

Transport system station

This model is a simulation of the MPS ® transport system

station from Festo Didactic. On this station workpieces are

to be transported to the individual station of an MPS ® 500-

FMS system.

Separating station

This model is a simulation of the MPS ® separating station

from Festo Didactic. On this station the material flow is

split The basic body for the cylinder is transferred to

conveyor 1 and the housing for the measuring instrument

is transported to conveyor 2 and transferred to the

neighbouring station.

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3. The CIROS ® Advanced Mechatronics system

Station model Description

Distributing station

This model is a simulation of the MPS ® distributing station

from Festo Didactic. On this station workpieces are to be

separated and passed on to the neighbouring station.

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3. The CIROS ® Advanced Mechatronics system

3.5

Controlling a station with

internal PLC

Each station in CIROS ® Advanced Mechatronics has an integrated

SIMATIC S7 simulator as internal PLC. The S7 simulator can execute

LDR, FCH, STL and GRAPH programs created in STEP 7.

When you start the simulation of a system, the internal PLC executes the

sample PLC program forming part of the station. This enables you to

familiarise yourself with the running of a system immediately after

modelling in the simulation.

Detailed information regarding the functional scope of the internal PLC

can be found on the CIROS ® online Help.

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3. The CIROS ® Advanced Mechatronics system

3.6

Controlling a station with

external PLC

If you are creating and testing your own PLC programs for the individual

stations of a system, we recommend that you download the programs

to an external PLC and execute them from this. The advantage of this is

that you can use the PLC and the programming system of your choice.

Also, the testing and diagnostic functions provided by the programming

system are thereby available to you in the PLC program for fault finding.

This includes the status display of PLC input/outputs and variables, the

online display of the PLC program and also the read-out of machine

statuses.

You do not need any additional hardware components if you use the

Soft-PLC S7-PLCSIM or CoDeSys SP PLCWinNT as external PLC.

Station of a system

PLC programming system STEP7

Soft PLC S7 PLCSIM

Information exchange with configuration using the external Soft-PLC S7-PLCSIM

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3. The CIROS ® Advanced Mechatronics system

Station of a system

EasyPort

PLC

If you use a hardware PLC as external PLC, you will need EasyPort and

the data cable for the exchange of input/output signals. EasyPort

transmits the input/output signals of the PLC to the OPC server EzOPC

via the serial or USB interface of the PC. The OPC server passes on the

data to the selected station during the system simulation and,

conversely, the statuses of the sensors and actuators of the

corresponding station are communicated to the external PLC.

Information exchange with configuration using an external hardware PLC

PLC programming system STEP7

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3. The CIROS ® Advanced Mechatronics system

3.7

Functions for setting

faults in a system

The dialog to set faults in a system is password protected. Access to

this dialog is available solely to trainers and teachers.

A list of typical faults is available for each station. Select one or several

faults from this list.

The task for trainees is to identify and describe the fault occurring

during system operation and to subsequently determine the cause of

the fault. The trainees enter the suspected fault in the dialog box for

error elimination.

If the fault has been correctly identified, the system then operates

correctly. The entries in the dialog box for fault elimination are logged

and can be viewed by trainers and teachers.

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3. The CIROS ® Advanced Mechatronics system

3.8

Functions for analysing a

system

With CIROS ® Advanced Mechatronics, you have numerous options to

monitor and analyse the operation of a system.

As soon as system simulation is active and the PLC programs of the

individual stations control the operation of the system, you can operate

and visually monitor the process.

The process is controlled via the pushbuttons and switches of the

individual control consoles.

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3. The CIROS ® Advanced Mechatronics system

LEDs on the sensors and valves indicate the electrical status of the

process components.

LEDs on the PLC inputs and outputs on the control console indicate

the status of the communication realised via these inputs and

outputs.

If compressed air is applied to a cylinder connection, then the

connection is highlighted in blue. The compressed air tubing itself is

not simulated.

The statuses of the PLC inputs/outputs are shown in separate

windows.

A Manual Operation window provides an overview of all process

statuses and process activities.

In the Manual Operation window you can also display the

communication links between two selected stations.

If you want to execute the sequence step-by-step, then use the Manual

Operation window as tool for control. By setting stops, you can stop the

process at defined points.

If a PLC program is not active during system simulation, you can use the

Manual Operation window to activate individual process activities,

whereby you can for example control the movement of a cylinder or the

switching on or off of an electric motor.

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3. The CIROS ® Advanced Mechatronics system

3.9

Directory and file

structure of CIROS ®

Advanced Mechatronics

Directory structure

following the installation

of CIROS ® Advanced

Mechatronics

Here you obtain information about the directory and file structure of

CIROS ® Advanced Mechatronics.

This information is useful if,

You want to make available the model of a system to other users,

You want to modify the sample PLC programs for the individual

stations of a system.

The following directory structure is created if you install CIROS ®

Advanced Mechatronics with the default settings offered.

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3. The CIROS ® Advanced Mechatronics system

Programs

. . . ciros advanced mechatronics.en

. . .

bin

. . .

Samples

FD_PLC_ADV

. . .

Models

Programs

MB4

S7

MPS500-FMS51

MPS500-FMS57

MPS System

with separating

Multi-Bit-IO

One-Bit-IO

313c___1

FMS50__1

MPSC_V22

Store

Model

Programs

MPS VE-PR

MPS VE-PR

MPS VE-PR-SO

Model

Programs

PLC programs for

MPS 500-FMS stations

PLC program for

MPS 500-FMS

transport system

PLC programs for

MPS Standard stations

PLC program for

MPS 500-FMS automated

warehouse station

MPS 501-FMS system

Workcell for

MPS 501-MPS system

PLC program for

MPS 501-FMS system

MPS 507-FMS system

MPS Standard system

with separating station

MPS Standard system with

distributing and testing stations

(multi bit communication)

MPS Standard system with

distributing and testing stations

(one bit communication)

MPS Standard system with

distributing, testing and

sorting stations

(one bit communication)

PLC and robot programs for

all MPS stations

34

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3. The CIROS ® Advanced Mechatronics system

Project structure for the

modelled systems

The S7 project with the sample PLC programs for the individual stations

is stored in the directory S7. These original PLC programs must not be

modified! The same applies to S7 programs and process models in the

folder Samples.

If you want to modify one or several of the sample PLC programs or of

the process models, you need to copy the directory Samples in another

subdirectory defined by you, where you carry out your modifications.

You can then download the modified programs to the internal PLC of the

appropriate station and execute it.

With this procedure, the default PLC programs used by CIROS ®

Advanced Mechatronics remain unchanged and can be reloaded again

to the internal PLC of a station at any time.

CIROS ® Advanced Mechatronics Assistant helps you copy models and

example PLC programs. For easy identification, copied models are called

user models and the original models are called reference models.

The example of a system is used to show what files form part of a

modelled system and what information is stored in these files. A system

is also known as a process model or workcell. All files which are part of

the graphic representation of the system are filed in the user-defined

subdirectory.

If additional CIROS ® Advanced Mechatronics systems are also stored in

the subdirectory viewed, then files with corresponding names are also

available for these systems. Moreover the list of bmp files is more

extensive. It is however difficult to allocate bmp files to individual

systems.

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3. The CIROS ® Advanced Mechatronics system

File Description

Example.mod Process model of a system named Example.

Example.ini Initialisation of the process model:

Example.prot Log of fault localisation:

Example.htm

Example.xls

Example.txt

The file contains all user-specific settings for the process model such as

window configuration, fault settings, etc.

It also contains a reference to the location and name of PLC programs to be

executed after simulation of the internal PLCs of the stations is started.

The file is read in teacher mode and displayed in the fault log window.

Exporting of fault log:

Modifications in the fault log are automatically exported into these files.

These files can then for example be viewed via Microsoft Internet Explorer or

Microsoft Excel.

Example.mcf Fault settings:

This file contains all the settings regarding the activation, start, duration and

type of a fault.

If this file exists in the process model directory, it overwrites the settings in

the ini-file. If it does not exist, then the fault settings filed in the ini-file are

used.

*.bmp Various bitmap files required for the graphic display of the system. The

Files for a process model

bitmap files required are dependent on which stations are used in the

system.

A system also includes PLC programs, which are executed either via an

internal or external PLC. These PLC programs control the running of

individual system stations. The file *.ini includes a reference to the

memory location of the PLC programs.

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3. The CIROS ® Advanced Mechatronics system

You need to keep this in mind if you want to copy a system you have

modelled yourself to another PC and simulate from there.

If you want to copy the process model of a system, the best way to

proceed is as follows:

Select all the files forming part of the system. These are all the files,

which have the name of the respective system and all the bitmap

files.

Copy the selected file to a subdirectory of the desired PC. The

subdirectory on the target PC must have the same name and the

same path as on your PC.

If the station is operated using the sample PLC programs, make sure

that the sample PLC programs on the new PC are stored in the same

path as on your PC. If this is not the case, start CIROS ® Advanced

Mechatronics on the new PC and download the copied process

model. Then download the desired PLC program from the relevant

directory on the new PC to the internal PLC of the individual system

stations. By downloading the PLC programs, the reference in the ini

file to the memory location of the PLC programs is automatically

corrected. The system can now be simulated.

If one or several stations of the system are controlled via your own

created PLC programs, then these programs must also be available

on the new PC. The PLC program must be downloaded to the

corresponding system stations on the new PC.

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4. Main control functions of CIROS ® Advanced

Mechatronics

Note

4.1

Creating a new MPS ®

Standard system from

preassembled station

models

This chapter describes the main control functions of CIROS ® Advanced

Mechatronics. Various options to activate commands are available via

MS Windows programs. In this description, commands are triggered via

entries in the menu bar. You can and should of course use the symbols

bar, appropriate key combinations or the context-sensitive menu with

the right mouse button.

Detailed information regarding the use of all the options of CIROS ®

Advanced Mechatronics can be found in the online Help for this

software package.

To enable you to create a wide range of different system, the library has

been extended with the addition of new station models. The new

standards regarding circuit diagram design are taken into consideration

in the PLC programs and circuit diagrams. "Old" and "new" standards

differ with regard to the designations of valve coils, pushbuttons and

switches as well as indicator lights.

The stations models for the configuration of a system are available in

two libraries:

MPS ® stations library,

MPS ® 500-FMS library.

If you want to model a new MPS ® Standard system, then use the models

from the MPS ® stations library.

This library contains the station models for the following:

Processing station,

Fluidic Muscle Press station,

Handling station,

Storing station,

Pick & Place station,

Testing station,

Buffer station,

Robot station,

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

Robot assembly station,

Sorting station,

Separating station

Distributing station.

Station models for an MPS ® Standard system are arranged directly next

to one another.

The alignment and connection of models is effected in a simple way via

specified coupling points on the models. The automatic alignment

ensures that the StationLink sensors of neighbouring stations are also

correctly positioned. The StationLink sensors are optical sensors which

transmit the communication signal.

A system can also be configured of just one station, whereby you can

teach all the training contents in CIROS ® Advanced Mechatronics for

which only a single station is required.

Due to the technological functions of the individual stations, only

certain combinations are permissible when modelling a system. The

possible combinations, i.e. subsequent stations, are indicated with grey

shading.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you

combine your

MPS ® Standard

stations

Distributing ‟ Standard

Distributing ‟ adjusted

for testing

Testing

Processing

Handling ‟ adjusted for

successor station

Handling ‟ adjusted for

termination

Buffer

Pick & Place

Fluidic Muscle Press

Separating

Storing ‟ Stock up

Storing ‟ Take out

Robot

Robot assembly

Sorting

Distributing –

Standard

Distributint – adjusted

for Testing

Permissible station combinations for MPS ® Standard systems

Testing

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Processing

Handling – adjusted

for successor station

Handling –adjusted

for termination

Buffer

Pick & Place


4. Main control functions of CIROS ® Advanced Mechatronics

This is how you

combine your

MPS ® Standard

stations

Distributing ‟ Standard

Distributing ‟ adjusted

for testing

Testing

Processing

Handling ‟ adjusted for

successor station

Handling ‟ adjusted for

termination

Buffer

Pick & Place

Fluidic Muscle Press

Separating

Storing ‟ Stock up

Storing ‟ Take out

Robot

Robot assembly

Sorting

Fluidic Muscle Press

Permisible station combinations for MPS ® Standard systems

Separating

Storing – Stock up

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Storing – Take out

Robot

Robot assembly

Sorting


4. Main control functions of CIROS ® Advanced Mechatronics

The distributing, handling and storing stations are available in two

variants. Depending on the combinations in which the stations are used,

individual sensors and stops are differently positioned and adjusted.

The distributing station can deposit workpieces at two different transfer

positions. The sensors which determine and detect the swivel angle on

the transfer module must be correspondingly set. The lower transfer

position is required for the testing station; all other stations operate

using the higher transfer position. The distributing station variants are

therefore correspondingly designated with distributing station –

adjusted for testing station and distributing station – standard design.

The handling station can deposit workpieces at two different positions:

Internally on the station or externally at the transfer position of the

sucessor station. The sensor which determines the transfer position of

the axis must be correspondingly positioned. If the handling station

forms the end of a system, then the workpieces are deposited on the

station itself. In this case you will require the variant handling station –

adjusted for termination. If there is a successor station, the workpieces

are deposited on the transfer position of the successor station. This

variant of the handling station is referred to as handling station –

adjusted for successor station.

The robot station can also deposit workpieces at two different

positions: Internally on the station or externally on the transfer position

of the successor station. The robot program automatically detects

whether or not a neighbouring station follows and adapts the robot

movement accordingly. This station can therefore both be used in the

middle of or as a last station in a production system.

Two sequences are available for the storing station: The station can

stock up or take our workpieces. Each sequence is realised via a

separate PLC program. If the station is at the beginning of the material

flow it thus forms the first station of a system ‟ consequently

workpieces are taken out. In this case you will require the variant

Storing Station ‟ Take out. If the storing station forms the end of a

system, then you use the variant Storing Station ‟ Stock up.

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4. Main control functions of CIROS ® Advanced Mechatronics

The operation of the system with the prepared PLC programs can only

be simulated fault-free if a system is correctly assembled.

The modelling of an MPS ® Standard system is explained with the help of

an example.

A combination consisting of the distributing, testing and sorting

stations is to be configured.

This is how you create an MPS ® Standard system

An MPS ® Standard system consisting of the distributing, testing and

sorting stations is to be created.

1. Start CIROS ® Advanced Mechatronics.

When CIROS ® Advanced Mechatronics is started, both the activity

window and the help window are opened.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

In CIROS ® Advanced Mechatronics Assistant open the folder which

contains the required process model. This is where a functional

description and technical documentation regarding the model are

available.

In addition, you can download a few prepared sample systems directly

from the Assistant.

If you do not require the information of the Assistant when starting

CIROS ® Advanced Mechatronics, deactivate the entry Open

Automatically of the assistant in the Help menu.

2. Activate the command New in the File menu. Click onto MPS ®

System.

The window Create MPS ® System is now displayed.

3. Select a directory as memory location for the new system and enter

the file name. Under file type, select CIROS ® Workcells (*.mod).

Then click onto Save.

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4. Main control functions of CIROS ® Advanced Mechatronics

4. The model of a blank system is displayed. By creating a new system,

a number of the following settings are automatically effected in

CIROS ® Advanced Mechatronics:

‟ The change into Edit Mode is effected,

‟ A table with the possible workpieces is made available,

‟ The view selected is Top View,

‟ The Model Libraries window is open.

5. A brief description of the model selected is displayed when you click

onto Details in the Model Libraries window.

Detailed information regarding the models in the library is available

on the online Help in the chapter CIROS ® Advanced Mechatronics.

You start Help by activating the command Examples and models of

CIROS ® Advanced Mechatronics in the menu Help.

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4. Main control functions of CIROS ® Advanced Mechatronics

6. First add the distributing station model. The distributing station is

available in two variants. Since the testing station follows the

distributing station in the sample system, select the entry

Distributing Station – Adjusted for Testing Station under MPS ®

Stations. A preview then displays the model. Now click onto the Add

button.

Alternatively, add a model by double clicking on the relevant model

corresponding model entry.

The system now consists of the distributing station – adjusted for

testing station model. The distributing station is shown in green as

it is still highlighted. Moreover the distributing station is connected

automatically to the workpiece table, since it has been added as the

first station.

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4. Main control functions of CIROS ® Advanced Mechatronics

7. Click outside of the station to cancel the highlighting.

A coupling point is shown on side of the station, which indicates that

the distributing station can be connected to a further station at this

point.

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4. Main control functions of CIROS ® Advanced Mechatronics

8. If the representation of the station is too small, you can change this

using the commands in the View menu.

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4. Main control functions of CIROS ® Advanced Mechatronics

9. Make sure that the Edit Mode is selected. You can establish this by

the check mark next to the Edit Mode command in the Modeling

menu. Now add the testing station as an additional station.

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4. Main control functions of CIROS ® Advanced Mechatronics

10. All stations are added at the same position in the workspace. Move

the newly added testing station, by highlighting the testing station

and, by holding down the left mouse button, moving the mouse

pointer to the desired position.

11. The two models are next to one another, but are not yet connected.

In order to ensure that the operating and transfer points coincide

during the production run of the system, the station models must be

appropriately aligned and connected.

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4. Main control functions of CIROS ® Advanced Mechatronics

12. Now align the testing station model with the distributing station

model.

To do so, click onto the lower, grey shaded coupling point of the

testing station. Hold down the left mouse button and drag the

coupling point to the coupling point of the distributing station.

The testing station is now connected to the distributing station.

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4. Main control functions of CIROS ® Advanced Mechatronics

13. Add the sorting station as the last station. This station is also shown

at the predefined position in the activity window.

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4. Main control functions of CIROS ® Advanced Mechatronics

14. Click onto the newly added, still highlighted station and move it up

next to the testing station.

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4. Main control functions of CIROS ® Advanced Mechatronics

15. Connect the sorting station model with the upper free coupling

point of the testing station model.

To do so, click onto the grey shaded coupling point of the sorting

station. Hold down the left mouse button and drag the coupling

point to the free coupling point of the testing station.

The highlighting of the model is cancelled as soon as you click

outside of the station model.

16. The system is configured. The communication links, realised via

optical sensors, are automatically established via the correct

positioning and connecting of the stations.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

Exit the edit mode as soon as your system is configured. Change to the

view mode to obtain a realistic 3D representation of the system.

It is not absolutely necessary to connect the workpiece table to a

station. You can position the workpiece table at any point within the

workspace.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you change to the view mode

1. Deactivate the Edit Mode command in the Modeling menu by

clicking onto the Edit Mode command. The check mark next to the

Edit Mode is removed.

2. A 3D representation of your system is now displayed. A top view is

also shown.

3. Close the Model Libraries window and select a perspective view of

the system.

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4. Main control functions of CIROS ® Advanced Mechatronics

4. To obtain a perspective view of the 3D model, select for example the

command Standard Views/Default Settings in the View menu. With

the commands under View you can move, rotate or zoom to obtain

an appropriate view of your system.

The system is correctly configured and connected. You can now

simulate system production right away.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

4.2

Creating an MPS ® 500-

FMS system from

preassembled station

models

Once you have created or modified a system, a Save prompt will be

displayed when you close the process model.

If you want to save the changes, answer the prompt with Yes or answer

with No if you want to discard the changes.

The station models to configure a system are available in two libraries:

MPS ® Stations library,

MPS ® 500-FMS library.

If you want to model an MPS ® 500-FMS system, then use the station

models from the MPS ® 500-FMS library.

The possible configuration levels of an MPS ® 500-FMS system are

based on the full configuration of the MPS ® 500-FMS system, where all

six working positions on the transport system are occupied by a station

or a combination of stations.

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4. Main control functions of CIROS ® Advanced Mechatronics

S

HH

P

V

Product output

Product input

Stock Assembly

HL RM

H

B

Processing Quality assurance

Small parts store

Presorting

V: Distributing station P: Testing station HL: Automated warehouse station

H: Handling station B: Processing station HH: Handling station

VI: Quality assurance station RM: Robot assembly station S: Sorting station

Full configuration of an MPS ® 500-FMS system

© Festo Didactic GmbH & Co. KG „ 572761 59

VI

The following form part of a full configuration of an MPS ® 500-FMS

system:

Pallet transport system station with 6 working positions for MPS ®

500-FMS stations,

Station combination consisting of distributing and testing stations,

Station combination consisting of handling and processing stations,

Quality assurance station,


4. Main control functions of CIROS ® Advanced Mechatronics

Robot assembly station,

Automated warehouse station,

Station combination consisting of handling and sorting stations.

The following rules apply to create MPS ® 500-FMS systems in different

configuration stages:

Only the listed six stations or station combinations can be

positioned on the transport system.

For each station or station combination, there is exactly one

permissible working position in the transport system. The position

can be seen from the full configuration of an MPS ® 500-FMS system.

Individual "positions" on the conveyor can remain unoccupied,

whereby individual stations or station combinations and their

associated production steps are omitted.

Example: The smallest MPS ® 500-FMS system consists of the

transport system station, the distributing and testing stations

combination for product input and the handling and processing

stations combination for product output.

The positioning and alignment of the models is effected simply via the

specified coupling points on the models.

In the case of MPS ® 500-FMS systems, the station models are aligned

with the transport system model and connected to it. The connection or

coupling points correspond to the stopper positions of the transport

system. As a result of establishing the connections, the default

communication links used are also simultaneously established.

The operation of the system can only be simulated error-free if a system

is correctly configured.

The modelling of an MPS ® 500-FMS system is shown using a simple

example. The sample system consists of a transport system, the

distributing and testing stations in the form of product input, the

handling and processing stations combination at the position for

processing and the handling and sorting stations in the form of product

output.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

This is how you create an MPS ® 500-FMS system

1. Start CIROS ® Advanced Mechatronics.

When CIROS ® Advanced Mechatronics is started both the activity

window and the Help window are displayed.

In CIROS ® Advanced Mechatronics Assistant open the folder which

contains the required process model. This is where a functional

description and technical documentation regarding the model are

available.

You can also download some prepared sample systems directly from

the Assistant.

If you do not need the information of the Assistant when starting

CIROS ® Advanced Mechatronics, then deactivate the entry for

automatically opening the Assistant in the Help menu.

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4. Main control functions of CIROS ® Advanced Mechatronics

2. Activate the New command in the File menu. Click onto MPS ®

System.

The Create MPS ® System window is now displayed.

3. Select a directory to store the new system. Enter the file name.

Under file type, select CIROS ® Workcells (*.mod). Then click onto

the Save button.

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4. Main control functions of CIROS ® Advanced Mechatronics

4. The model of a blank system is now displayed. By creating a new

system, some settings in CIROS ® Advanced Mechatronics are

automatically effected such as:

‟ Changing into the Edit mode,

‟ A table with possible workpieces is made available,

‟ The view selected is Top View,

‟ The window Model Libraries is open.

5. A short description of the selected model is displayed if you click

onto Details in the Model Libraries window.

Detailed information regarding the models in the library is available

on the online help in the chapter CIROS ® Advanced Mechatronics.

Help is started by activating the command Examples and Models of

CIROS ® Advanced Mechatronics in the Help menu.

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4. Main control functions of CIROS ® Advanced Mechatronics

6. First, insert the transport system model from the MPS ® 500-FMS

library by clicking onto Transport System. A preview then displays

the model. Now click onto the Add button.

Alternatively, you can add a model by clicking onto the

corresponding model entry.

The system now consists of the model of the transport system,

which is shown in green as it is still highlighted.

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4. Main control functions of CIROS ® Advanced Mechatronics

7. Click outside of the model to cancel the highlighting.

Three coupling points are shown on each of the longitudinal sides of

the transport system model. These indicate that the transport

system model can be connected with additional models at these

points.

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4. Main control functions of CIROS ® Advanced Mechatronics

8. Move the transport system model into the centre of the workspace.

To do so, highlight the model via a mouse click. Then drag the

mouse pointer to the desired position by holding the left mouse

button down.

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4. Main control functions of CIROS ® Advanced Mechatronics

9. Now add the station combination for product input as a further

model by double clicking onto Product Input.

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4. Main control functions of CIROS ® Advanced Mechatronics

10. All stations are added at the same position in the workspace. Move

the newly added product input station combination. The operating

position for product input is at the bottom left of the transport

system.

11. The two models are next to one another, but are not yet connected.

To ensure that the operating and transfer points coincide during the

production run of the system, the models must be appropriately

aligned and connected.

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4. Main control functions of CIROS ® Advanced Mechatronics

12. Now align the model for product input with the transport system

model by clicking onto the grey shaded connecting point of the

stations for product input. Hold down the left mouse button and

drag the connecting point onto the connecting point of the transport

system.

The station combination for product input is now connected to the

transport system.

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4. Main control functions of CIROS ® Advanced Mechatronics

13. Next enter the station combination for the processing sequence by

double clicking onto Processing in the MPS ® 500-FMS library. This

station combination is also shown at the predefined position in the

activity window.

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4. Main control functions of CIROS ® Advanced Mechatronics

14. Connect the newly added, still highlighted model to the lower

middle connecting point of the transport system model by

clicking onto the grey shaded coupling point of the highlighted

processing model. By holding down the left mouse button drag the

coupling point to the lower, middle coupling point of the transport

system model.

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4. Main control functions of CIROS ® Advanced Mechatronics

15. Finally, add the model for product output. Again, this model is

shown at the predefined position in the activity window.

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4. Main control functions of CIROS ® Advanced Mechatronics

16. Move the newly added product output station combination. The

operating position for product output is at the top left of the

transport system.

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4. Main control functions of CIROS ® Advanced Mechatronics

17. Connect the product output model to the top left connecting point of

the transport system.

The highlighting of the model is cancelled as soon as you click

outside of the station model.

18. The system is created. The default communication links used have

been automatically established during modelling of the system.

19. Now exit the Edit Mode and change to the View Mode to obtain a

realistic 3D representation of the system.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you change into the view mode

1. Deactivate the Edit Mode command in the Modeling menu by

clicking onto the Edit Mode command. The check mark next to Edit

Mode is removed.

2. A 3D display of your system is now displayed which also includes a

top view.

3. Close the Model Libraries window. This will give you more space for

the system representation.

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4. Main control functions of CIROS ® Advanced Mechatronics

4. To obtain a perspective view of the 3D model, select for example the

Standard Views/Default Settings command in the View menu. With

the commands under View you can move, rotate and zoom to obtain

an appropriate view of your system.

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4. Main control functions of CIROS ® Advanced Mechatronics

5. The workpiece table can be positioned at a different point within

your workspace at any time. Activate the Edit Mode command in the

Modeling menu and move the workpiece table to the desired

position. Deactivate the Edit Mode command in the Modeling menu

and generate an appropriate view of the system.

The system is created and correctly connected. You can now simulate

system product straight away.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

4.3

Modifying an existing

system

If you have newly created or modified the process model of a system, a

save prompt will be displayed when you close the process model.

If you want to save the changes, then answer the prompt with Yes, or

answer the prompt with No, if you want to discard the changes.

You can modify the model of a system and for example add further

stations. How you proceed for this and what you need to observe

depends on what communication links are to be used within the system.

In MPS ® Standard systems, optical sensors are used as standard to

effect communication.

If the stations of an MPS ® Standard system are correctly positioned

and connected, using the connecting points, then the

communication links are automatically established by means of this

process.

If you change an MPS ® Standard system for which you have realised

multi-bit communication via I/O connection, then the

communication links must be re-established.

If you only use the default communication links prepared and want

to establish these, then activate the command Create

Communication Links in the Modeling menu.

All other communication links are to be established in the Manual

Operation window.

Multi-bit communication via I/O connection is available as standard

in MPS ® 500-FMS systems.

When modelling, or also modifying such a system, the

communication links are set up automatically.

However, if you modify an MPS ® 500-FMS system where you are not

using the prepared default communication links, you need to set up

the communication links yourself after modelling. User-defined

communication links are set-up in the Manual Operation window.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you modify an already created system

1. Start CIROS ® Advanced Mechatronics.

2. Download the desired system by activating the Open command in

the file menu.

3. The Open File window is now displayed.

Workcell (*.MOD) must be set as file type. Change into the directory

in which the process model of the system is stored. Select the

desired file and click onto the Open button.

4. View mode is set as standard. To change the system, change into

edit mode by activating the Edit Mode command in the Modeling

menu.

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4. Main control functions of CIROS ® Advanced Mechatronics

5. If you want to display information regarding the individual stations

of the system, you need to highlight the respective station via a

mouse click. Highlighted stations are shown in colour.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

6. Open the context-sensitive menu via the right mouse button.

Activate the Properties command.

The Object Properties window is now open. The name indicates that

the highlighted station is a testing station.

Close the window when you have obtained all the necessary

information.

You will need the Object Properties function if you use a station in a

system several times and wish to identify the individual stations. You

identify a station by its name.

Example: If you are using the buffer station twice in your system, the

name of the station added first is Buffer and the name of the

subsequently added buffer station is Buffer_1.

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4. Main control functions of CIROS ® Advanced Mechatronics

7. If you now wish to add another station to your system, change to the

top view representation in View by activating the Standard

Views/Top View command in the View menu.

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4. Main control functions of CIROS ® Advanced Mechatronics

8. Select an appropriate representation of the system via zooming,

moving or rotating the system.

9. Make sure that edit mode is selected. You can establish this by the

check mark next to the command Edit Mode in the Modeling menu.

10. Now open the model libraries by activating the Model Libraries

command in the Modeling menu.

11. In the case of the sample system, this is an MPS ® Standard system.

For modifications to the system, you will need the stations of the

MPS ® Stations library. Open the library by clicking onto the +

symbol in front of MPS ® Stations library.

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4. Main control functions of CIROS ® Advanced Mechatronics

12. Carry out your modifications to the system. If you want to expand

the system by adding assembly functions, then add for example the

Pick & Place and Fluidic Muscle Press stations between the sorting

and testing stations.

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4. Main control functions of CIROS ® Advanced Mechatronics

13. To add the desired stations, highlight the sorting station and move

it up.

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4. Main control functions of CIROS ® Advanced Mechatronics

14. Now insert the Pick & Place station by double clicking the library

entry Pick & Place Station.

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4. Main control functions of CIROS ® Advanced Mechatronics

15. Position the added station next to the testing station by clicking

onto the highlighted Pick & Place station and move the mouse

pointer to the desired position by holding down the left mouse

button.

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4. Main control functions of CIROS ® Advanced Mechatronics

16. Connect the new Pick & Place station to the testing station by

clicking onto the bottom, grey shaded coupling point of the Pick &

Place station. Drag the coupling point to the coupling point of the

testing station by holding down the left mouse button.

The testing and Pick & Place stations are now interconnected.

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4. Main control functions of CIROS ® Advanced Mechatronics

17. Use the same method to add the Fluidic Muscle Press station.

Connect this station to the Pick & Place station.

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4. Main control functions of CIROS ® Advanced Mechatronics

18. Finally, connect the sorting station to the Fluidic Muscle Press

station.

To do so, highlight the sorting station. Then drag the coupling point

of this station to the unoccupied coupling point of the Fluidic

Muscle Press station whilst holding the left mouse button.

19. The changes to the system are completed. The communication links,

realised via the optical StationLink sensors, are automatically set up

via the correct positioning and connection of the stations.

Close the library and change to the view mode to obtain a realistic

3D display of the system.

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4. Main control functions of CIROS ® Advanced Mechatronics

20. Deactivate edit mode in the Modeling menu by clicking onto the

Edit Mode command. The check mark next to Edit Mode disappears.

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4. Main control functions of CIROS ® Advanced Mechatronics

21. To obtain a perspective view of the 3D model, select for example the

Standard Views/Default Settings command in the View menu. By

using the commands under View you can move, rotate or zoom to

obtain an appropriate view of your system.

22. Save the modified status of the system by activating Save in the File

menu if you want to keep the current file name. Select the Save as

command if you want to save the system under a new name.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

4.4

Creating and monitoring

communications links in a

system

MPS ® Standard systems

In the same way as you can expand a system by adding new stations

you can also remove existing stations of a system, whereby you proceed

as follows:

Highlight the respective station. Open the context-sensitive menu via

the right mouse button, where you activate the Remove command. The

station highlighted is removed.

In MPS ® system, the communication exchange is realised differently

between the individual stations of a system.

In an MPS ® Standard systems, communication takes place in the

form of 1-bit connection via optical sensors as standard. As soon as

the stations of a system are correctly positioned and connected with

the help of the coupling points, the optical sensors are also correctly

positioned to transmit communication signals. The prerequisites for

error-free transmission of communication information are therefore

in place.

The absolute addresses of the PLC inputs and outputs of a station

connected to the optical sensors can be found in the allocation list

of the sample PLC program. You will find the technical

documentation and information regarding the sample PLC program

in the CIROS ® Advanced Mechatronics Assistant.

To open the CIROS ® Advanced Mechatronics Assistant, activate the

Examples and Models of CIROS ® Advanced Mechatronics

command in the Help menu.

If you have expanded the 1-bit communication in a MPS ® Standard

system to multi-bit communication via I/O connection, then you will

need to create the additionally required communication links in the

virtual system.

Only if these communication links have been set up, can the

information exchange between the system stations take place

during simulation.

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4. Main control functions of CIROS ® Advanced Mechatronics

Different PLC inputs and outputs are available for the transmission

of communication information.

To enable you to work with a networked system promptly, the

communication links between the stations are already prepared.

You can establish these at the click of a button (Modeling/I/O

Configuration/Create Communication Links), whereby specific PLC

outputs of a station are connected to specific PLC inputs of

neighbouring stations. Conversely, a number of PLC inputs of a

station are of course also connected with PLC outputs of

neighbouring stations.

You can see all I/O communication links set up for an MPS ® system

in the Manual Operation window.

The prepared default communication links are shown as examples for

an MPS ® Standard system. The system consists of the distributing,

testing and sorting stations. If other MPS ® Standard stations are

integrated into a system, the connections between the stations are set

up along the above lines.

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4. Main control functions of CIROS ® Advanced Mechatronics

Optical

sensors

Control

console

Additional

PLC inputs/

outputs for

communication

Distributing station Testing station Sorting station

IP_FI


I4 Q6

I5 Q7

Q4 I6

Q5 I7

COMM_I0 COMM_Q4

COMM_I1 COMM_Q5

COMM_I2 COMM_Q6

COMM_I3 COMM_Q7

COMM_Q0 COMM_I4

COMM_Q1 COMM_I5

COMM_Q2 COMM_I6

COMM_Q3 COMM_I7













IP_N_FO IP_FI


I4 Q6

I5 Q7

Q4 I6

Q5 I7

COMM_I0 COMM_Q4

COMM_I1 COMM_Q5

COMM_I2 COMM_Q6

COMM_I3 COMM_Q7

COMM_Q0 COMM_I4

COMM_Q1 COMM_I5

COMM_Q2 COMM_I6

COMM_Q3 COMM_I7

The prepared default communication links for an MPS ® Standard system

Note

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IP_N_FO


I4 Q6

I5 Q7

Q4 I6

Q5 I7

COMM_I0 COMM_Q4

COMM_I1 COMM_Q5

COMM_I2 COMM_Q6

COMM_I3 COMM_Q7

COMM_Q0 COMM_I4

COMM_Q1 COMM_I5

COMM_Q2 COMM_I6

COMM_Q3 COMM_I7

PLC input I5 must be used for communication transfer. Input I5 is

coupled to an EMERGENCY-STOP and indicates whether or not

EMERGENCY-STOP is available.

PLC inputs/outputs COMM_I0 to COMM_I7 and COMM_Q0 to

COMM_Q7 are only available in the case of the virtual MPS ® stations

for communication. Real MPS ® stations do not have these

inputs/outputs for communication as standard.

The tables below list the allocation of the symbolic PLC addresses used

for communication to the absolute PLC addresses.


4. Main control functions of CIROS ® Advanced Mechatronics

Distributing station Testing station Sorting station

Symbolic

address

Absolute

address

Symbolic

address

Absolute

address

Symbolic

address

Absolute

address

IP_FI I0.7 IP_FI I0.7 IP_N_FO Q0.7

IP_N_FO Q0.7

I4 I1.4 I4 I1.4 I4 I1.4

I5 I1.5 I5 I1.5 I5 I1.5

I6 I1.6 I6 I1.6 I6 I1.6

I7 I1.7 I7 I1.7 I7 I1.7

Q4 Q1.4 Q4 Q1.4 Q4 Q1.4

Q5 Q1.5 Q5 Q1.5 Q5 Q1.5

Q6 Q1.6 Q6 Q1.6 Q6 Q1.6

Q7 Q1.7 Q7 Q1.7 Q7 Q1.7

COMM_I0 I2.0 COMM_I0 I2.0 COMM_I0 I2.0

COMM_I1 I2.1 COMM_I1 I2.1 COMM_I1 I2.1

COMM_I2 I2.2 COMM_I2 I2.2 COMM_I2 I2.2

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4. Main control functions of CIROS ® Advanced Mechatronics

Distributing station Testing station Sorting station

Symbolic

address

Absolute

address

Symbolic

address

Absolute

address

Symbolic

address

COMM_I3 I2.3 COMM_I3 I2.3 COMM_I3 I2.3

COMM_I4 I2.4 COMM_I4 I2.4 COMM_I4 I2.4

COMM_I5 I2.5 COMM_I5 I2.5 COMM_I5 I2.5

COMM_I6 I2.6 COMM_I6 I2.6 COMM_I6 I2.6

COMM_I7 I2.7 COMM_I7 I2.7 COMM_I7 I2.7

Absolute

address

COMM_Q0 Q2.0 COMM_Q0 Q2.0 COMM_Q0 Q2.0

COMM_Q1 Q2.1 COMM_Q1 Q2.1 COMM_Q1 Q2.1

COMM_Q2 Q2.2 COMM_Q2 Q2.2 COMM_Q2 Q2.2

COMM_Q3 Q2.3 COMM_Q3 Q2.3 COMM_Q3 Q2.3

COMM_Q4 Q2.4 COMM_Q4 Q2.4 COMM_Q4 Q2.4

COMM_Q5 Q2.5 COMM_Q5 Q2.5 COMM_Q5 Q2.5

COMM_Q6 Q2.6 COMM_Q6 Q2.6 COMM_Q6 Q2.6

COMM_Q7 Q2.7 COMM_Q7 Q2.7 COMM_Q7 Q2.7

Allocation of symbolic PLC addresses to the absolute PLC addresses for a number of MPS ® Standard

stations

MPS ® 500-FMS systems

In MPS ® 500-FMS systems, multi-bit communication is available as

standard. Multi-bit communication is essentially realised via I/O

connection. However, in addition to the coupling of PLC inputs and

outputs, the optical StationLink sensors are used for the

transmission of communication information.

As soon as the stations of a system are correctly positioned and

connected by means of the coupling points, the prepared default I/O

communications links are also automatically established.

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4. Main control functions of CIROS ® Advanced Mechatronics

The information exchange between the system stations during

simulation can take place.

Both the absolute and symbolic addresses of the PLC

inputs/outputs of a station used for communication can be found in

the allocation list of the sample PLC program. Technical

documentation and information regarding the sample PLC program

of a station can be found in CIROS ® Advanced Mechatronics

Assistant.

To open CIROS ® Advanced Mechatronics Assistant, activate the

Examples and Models of CIROS ® Advanced Mechatronics

command in the Help menu.

Different PLC inputs and outputs are available for the transmission

of communication information.

To enable you to work promptly with a networked system, the

communication links between the stations are prepared. They are

automatically established during modelling or via the press of a

button (Modeling/I/O Configuration/Create Communication Links),

whereby specific PLC inputs and outputs of a station are connected

to the PLC inputs and outputs of neighbouring stations. The sample

PLC programs provided use a part of these communication links.

The communication interfaces between all stations are described in

CIROS ® Advanced Mechatronics Assistant.

All I/O communication links established for an MPS ® system can be

identified in the Manual Operation window.

The prepared communication links are shown as examples for an MPS ®

500-FMS system. The station consists of the transport system station

and the distributing and testing stations in the form of product input.

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4. Main control functions of CIROS ® Advanced Mechatronics

Optical

sensors

Control

console

Additional

PLC inputs/

outputs for

communication

Distributing station Testing station Transport system

IP_FI


I4 Q6

I5 Q7

Q4 I6

Q5 I7

COMM_I0 COMM_Q4

COMM_I1 COMM_Q5

COMM_I2 COMM_Q6

COMM_I3 COMM_Q7

COMM_Q0 COMM_I4

COMM_Q1 COMM_I5

COMM_Q2 COMM_I6

COMM_Q3 COMM_I7


IP_N_FO IP_FI


I4









I5

Q4

Q5

station

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I6

I7

Q6

Q7

COMM_I0 COMM_Q4

COMM_I1 COMM_Q5

COMM_I2 COMM_Q6

COMM_I3 COMM_Q7

COMM_Q0 COMM_I4

COMM_Q1 COMM_I5

COMM_Q2 COMM_I6

COMM_Q3 COMM_I7











ST1_OUT0

ST1_OUT1

ST1_OUT2

ST1_OUT3

ST1_IN0

ST1_IN1

ST1_IN2

ST1_IN3

ST1_COMM_I0

ST1_COMM_I1

ST1_COMM_I2

ST1_COMM_I3

ST1_COMM_Q0

ST1_COMM_Q1

ST1_COMM_Q2

ST1_COMM_Q3

The prepared default communication links for a small MPS ® 500-FMS system; only working position 1 of the

transport system is allocated

Note

The transport system station has the communication interface

shown for each working position. The working position is identical to

the stopper position.

PLC input I5 of the individual stations must not be used for

communication transfer. Input I5 is coupled to the EMERGENCY-

STOP and indicates whether or not EMERGENCY-STOP is available>.

A 1-signal is applied at input 15 if EMERGENCY-STOP is not

actuated.


4. Main control functions of CIROS ® Advanced Mechatronics

PLC inputs/outputs COMM_I0 to COMM_I7, COMM_Q0 to

COMM_Q7, ST1_COMM_I0 to ST1_COMM_I3, ST1_COMM_Q0 to

ST1_COMM_Q3 are only available for communication for the virtual

MPS ® stations. Real MPS ® stations do not have these input/outputs

as standard for communication.

A description of the communication interfaces between all the

stations of an MPS ® 500-FMS system and therefore also of the

prepared default communication links can be found in CIROS ®

Advanced Mechatronics Assistant.

The tables show the allocation of the symbolic PLC addresses used for

communication to the absolute PLC addresses.

Distributing station Testing station Transport system station

Symbolic

address

Absolute

address

Symbolic

addresse

IP_FI I0.7 IP_FI I0.7

Absolute

address

IP_N_FO Q0.7

Symbolic

address

I4 I1.4 I4 I1.4 ST1_IN0 I2.0

I5 I1.5 I5 I1.5 ST1_IN1 I2.1

I6 I1.6 I6 I1.6 ST1_IN2 I2.2

I7 I1.7 I7 I1.7 ST1_IN3 I2.3

Absolute

address

Q4 Q1.4 Q4 Q1.4 ST1_OUT0 Q2.0

Q5 Q1.5 Q5 Q1.5 ST1_OUT 1 Q2.1

Q6 Q1.6 Q6 Q1.6 ST1_OUT 2 Q2.2

Q7 Q1.7 Q7 Q1.7 ST1_OUT 3 Q2.3

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4. Main control functions of CIROS ® Advanced Mechatronics

Distributing station Testing station Transport system station

Symbolic

address

Absolute

address

Symbolic

address

Absolute

address

Symbolic

address

COMM_I0 I2.0 COMM_I0 I2.0 ST1_COMM_I0 I2.4

COMM_I1 I2.1 COMM_I1 I2.1 ST1_COMM_I1 I2.5

COMM_I2 I2.2 COMM_I2 I2.2 ST1_COMM_I2 I2.6

COMM_I3 I2.3 COMM_I3 I2.3 ST1_COMM_I3 I2.7

Absolute

address

COMM_I4 I2.4 COMM_I4 I2.4 ST1_COMM_Q0 Q2.4

COMM_I5 I2.5 COMM_I5 I2.5 ST1_COMM_Q1 Q2.5

COMM_I6 I2.6 COMM_I6 I2.6 ST1_COMM_Q2 Q2.6

COMM_I7 I2.7 COMM_I7 I2.7 ST1_COMM_Q3 Q2.7

COMM_Q0 Q2.0 COMM_Q0 Q2.0

COMM_Q1 Q2.1 COMM_Q1 Q2.1

COMM_Q2 Q2.2 COMM_Q2 Q2.2

COMM_Q3 Q2.3 COMM_Q3 Q2.3

COMM_Q4 Q2.4 COMM_Q4 Q2.4

COMM_Q5 Q2.5 COMM_Q5 Q2.5

COMM_Q6 Q2.6 COMM_Q6 Q2.6

COMM_Q7 Q2.7 COMM_Q7 Q2.7

Allocation of symbolic PLC addresses to the absolute PLC addresses for a number of MPS ® 500-FMS stations

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

Display of communication

links

The transport system station has the communication interface shown

for each of the six working positions. The name of the communication

variable includes a reference to the working position for the purpose of

differentiation. The working position is identical to the stopper position.

The communication variable for working position 2, i.e. the processing

working position, starts with ST2_. These variables do of course have a

different absolute address than the variable starting with ST1_.

You will find the complete list of the communication variables of the

transport system station in CIROS ® Advanced Mechatronics Assistant.

Communication links are created and displayed in the Manual

Operation window.

The status of a communication link is identified by the graphic

representation of the connection.

Process Activities are displayed in the lefthand part of the window.

These are the variables to which the process model simulation reacts.

You can change the value of these variables in that you can for example

apply 1-signal at a communication input or a valve coil.

The righthand part of the window shows the process activities. These

are the variables which adjust the simulation of the process model. The

user cannot change the value of these variables. Examples of process

activities are sensor signals or also the values of communication

outputs.

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4. Main control functions of CIROS ® Advanced Mechatronics

Communication links are shown in the middle section. Communication

links form part of the I/O connections.

The signal flow of a communication links runs from right to left. You can

see this by the orientation of the arrow at the end of the links.

The status of a communication link can be identified by the colour of the

links:

Blue: Link is selected,

Red: Link has the value 0,

Green: Link has the value 1.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you establish the prepared default communication links

1. Make sure that the desired MPS ® is loaded. The example selected

shows an MPS ® 500-FMS system. This system consists of a

transport system, the distributing and testing stations in the form of

product input and the handling and sorting stations in the form of

product output.

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4. Main control functions of CIROS ® Advanced Mechatronics

2. Check whether the communication links have already been

established via the coupling of PLC inputs and outputs. To do so,

open the Manual Operation window by activating the Manual

Operation command in the Modeling window.

3. If the middle section of the window with the heading I/O

Connections is not displayed, then open the context-sensitive menu

via the right mouse button.

You open the context-sensitive menu by moving the mouse pointer

into the Manual Operation window and then pressing the right

mouse button. Select the command Show I/O connections.

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4. Main control functions of CIROS ® Advanced Mechatronics

4. Double click the + symbol in front of the individual stations in the

Manual Operation window to display the entries regarding all the

stations and, insofar as available, also the communication links.

No communication links are displayed in the I/O Connections

window. Therefore, no communication links are established. They

have been deleted by the user at an earlier stage.

5. To create the prepared default communication links activate the

Create Communication Links command in the Modeling menu under

I/O Confiuration.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

6. The communication links are set up and shown in the Manual

Operation window under I/O Connections in the form of graphic

connections between the respective communication input/outputs.

7. You can now simulate the running of the prepared PLC programs.

In the case of MPS ® 500-FMS systems the default communication

links used are already created automatically via I/O connection

during the modelling.

Provided that you do not make any changes to the PLC programs

and the communication interfaces, you do not need to create the

communication links.

With MPS ® Standard systems the prepared communication links

are not automatically created via I/O connection.

If you want to realise multi-bit communication for MPS ® Standard

systems via I/O connection and use the prepared communication

links for this, you need to create the communication links using the

described menu commands.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you delete the default communication links

1. Make sure that the desired MPS ® system is loaded. The selected

example shows an MPS ® 500-FMS system. The system consist of a

transport system, the distributing and testing stations in the form of

product input and the handling and sorting stations as product

output.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

2. Activate the Delete Communication Links command under I/O

Configuration in the Modeling menu.

3. All default communication links are now deleted. You can establish

this in the Manual Operation window in the I/O Connections

section. Connections are displayed neither between the

communication inputs/outputs of the distributing and testing

stations nor between the communication input/outputs of the

testing and transport system stations. The same applies for the

product output and transport system stations.

The Delete Communication links command deletes all default

communication links. This command does not delete user-defined

communication links.

Delete individual communication connections with the command

Remove I/O Connection in the context sensitive menu for the manual

operation window.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you create user-defined communication links

You can create or delete individual communication links yourself at any

time. It is however important that you use communication interfaces

other than the prepared default interfaces in the PLC programs for the

stations of your system or, for example, if you only want to create

exactly those connections which are evaluated by the PLC programs.

1. Load the desired MPS ® system. The selected example displays an

MPS ® Standard system, which consists of the distributing, testing

and sorting stations.

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4. Main control functions of CIROS ® Advanced Mechatronics

2. Open the Manual Operation window by clicking onto the Manual

Operation command in the Modeling menu. This window is divided

into three parts.

If the middle part of the window with the heading I/O Connections is

not shown, then open the context-sensitive menu via the right

mouse button.

Open the context-sensitive menu by moving the mouse pointer into

the Manual Operation window and then pressing the right mouse

button. Select the Show I/O Connections command.

3. Double click the + Symbol in front of the stations to display all

entries regarding the stations. No connections are shown between

the communication inputs and outputs of the stations.

Consequently, none of the communication links for the system have

been created as yet.

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4. Main control functions of CIROS ® Advanced Mechatronics

4. You require a connection between the PLC output Q4

Communication of the testing station and the PLC input I6

Communication of the distributing station.

5. In the righthand section of the window scroll down the items of the

testing station into the viewable area of the window.

On the lefthand side of the window scroll down the items of the

distributing station into the viewable section.

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4. Main control functions of CIROS ® Advanced Mechatronics

6. To establish the desired connection, click onto the Q4

Communication line of the testing station. The line is now

highlighted. Move the mouse pointer onto the blue double arrow

next to the highlighted entry. The mouse pointer now changes into a

rectangle with connection lines.

You can now establish the connections. Press the left mouse button

and whilst holding down the left mouse button, move the mouse

pointer to the arrow next to the entry I6 Communication of the

distributing station. Then release the mouse button again. The

communication link has now been created.

7. If you now click onto Q4 Communication of the testing station, the

entry 16 Communication of the distributing station connected to

this output is automatically highlighted.

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4. Main control functions of CIROS ® Advanced Mechatronics

8. Next, you want to establish a connection between the PLC input I4

Communication of the testing station and the PLC output Q6

Communication of the distributing station.

9. You now need to select the desired output Q6 Communication of the

distributing station in the righthand window under Process Status.

On the lefthand side of the window then scroll the 14

Communication entry of the testing station into the viewable

section of the window.

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10. To establish the desired connection, click onto the entry Q6

Communication of the distributing station. The entry is now

highlighted. Then move the mouse pointer onto the blue double

arrow next to the highlighted entry. The mouse pointer now changes

into a rectangle with connecting lines.

You can now establish the connection. Press the left mouse button

and, whilst holding down the mouse button, move the mouse

pointer up to the arrow next to the 14 Communication entry of the

testing station, then release the mouse button again. The

communication link is now set up.

11. Proceed in the same way if you require further communication links

between the stations of your system.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you delete user-defined communication links

1. Load the desired MPS ® system. The example selected displays an

MPS ® Standard system, which consists of the distributing, testing

and sorting stations.

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2. Open the Manual Operation window by clicking onto the Manual

Operation command in the Modeling menu.

If the middle section of the window with the heading I/O

Connections is not displayed, then open the context-sensitive menu

via the right mouse button.

To do so, move the mouse pointer into the Manual Operation

window and then press the right mouse button. Now select the

Show I/O Connections command.

3. Double click the + symbol of the individual stations to display the

entries for the stations.

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4. Main control functions of CIROS ® Advanced Mechatronics

4. Click onto the entry, whose connection you want to delete. In this

exampIe, this is the I4 Communication entry of the testing station.

If you want to see the communication output with which

14 Communication is connected, then scroll down in the righthand

section of the window until the connection is fully displayed.

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5. Click onto the I4 Communication entry of the testing station again

or onto the associated entry Q6 Communication of the distributing

station. Open the context-sensitive menu via the right mouse button

and select the Remove IO Connection command.

6. The communication link has been deleted.

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4. Main control functions of CIROS ® Advanced Mechatronics

4.5

Simulating a system

The production run of the system can be simulated as soon as a system

is modelled and the necessary communication links are set up.

The following preconditions must be fulfilled for MPS ® Standard

systems:

The stations must be correctly positioned next to each other and

connected.

If the stations are correctly positioned, then the position and

alignment of the StationLink sensor which transmit the

communication signal are also correct. The communication links are

thus correctly established.

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Note

A PLC program which controls the operation of the station must be

available for each station.

The PLC program can be executed either via the internal S7 PLC or

an external controller.

If you are using the default settings of the software, then the sample

PLC program of the station is automatically loaded to the internal S7

PLC and executed when simulation is started.

If no PLC program is active, then the user can systematically control

individual process components of the system by using the manual

operation window functions.

The user can disconnect the connection between station models and

PLC selectively in order to manually control individual process

components.

The prerequisites for MPS ® 500-FMS systems are as follows:

The stations must be correctly positioned and aligned with the

transport system.

The communication links between the PLC inputs and outputs of the

stations must be established. This is effected automatically for the

prepared communication links as a result of the correct positioning

and alignment of the stations on the transport system.

A PLC program must be available for each station, which controls the

operation of the station.

The PLC program can be executed either via the internal S7 PLC or

an external controller.

If you are using the default settings of the software, then the sample

PLC program of the station is automatically loaded to the internal S7

PLC and executed.

If no PLC program is active, then the user can selectively control

individual process components of the system using the manual

operation window functions.

If you simulate a system that is incorrectly configured, the individual

process components will behave differently during simulation than

expected.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

As soon as system simulation is active, you can monitor the visual

simulation and therefore the production sequence of the system in the

activity window.

Certain information is always available to you.

The file name and path data of the loaded system are shown in the

header line.

The status bar informs you regarding the operating status of the

system:

A field to the right displays whether simulation is active or stopped.

Stopped: The simulation mode is not active. The system is not

being simulated

Not simulated.

Cycle: The system is being simulated.

Running: The system is being simulated.

The field on the left indicates the simulation time.

In CIROS ® Advanced Mechatronics the two simulation modes Cycle and

Running are identical.

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This is how simulation is switched on and off again

1. Make sure that the system is in the initial position by executing the

Reset Workcell command in the Simulation menu.

2. Activate the Start command in the Simulation menu.

The simulation is active. You can identify the simulation mode in the

status line via the Running entry.

Alternatively you can also activate simulation via the Start Cycle

menu entry or via the Stopped button in the status bar.

3. To stop simulation, click Stop in the Simulation menu.

Alternatively you also click onto the Running field in the status bar.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

4.6

Operating and monitoring

a system

Control console of MPS Standard station

I4

I5

Q4

Q5

GND

I/O

Process module

Start Stop

As soon as simulation is active, you can operate and monitor the

system.

Reset Auto/Man

Q1 Q2

Proceed as follows if you want to save a modelled system after

simulation is executed: First activate the command Reset Workcell in

the Simulation menu. The system moves into the initial position. All

workpieces are removed. Then activate the required command to save

the system.

If system simulation is active, you can operate each station controlled

via the sample PLC program using the pushbuttons and switches of the

corresponding control console. You can identify the status of simulation

on the status bar.

Control console of transport system station

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Depending on the system combination, different production processes

are executed. Pneumatic cylinders or measuring instruments can be

produced. The individual production processes require different

workpieces. Missing parts are designated for individual stations.

Workpieces Suitable for systems with

Correct workpieces: Basic

cylinder body of different types

Black

Red

Metal

Workpiece of incorrect height

and incorrectly drilled hole:

Basic cylinder body

Blue

Correct workpieces:

Housings for measuring

instruments in different designs

Black

Red

Metal

Processing station

Storage station

Buffer station

Testing station

Robot station

Robot assembly station

Sorting station

Separating station

Distributing station

Processing station

Testing station

Processing station

Fluidic Muscle Press station

Storage station

Pick & Place station

Buffer station

Testing station

Sorting station

Separating station

Distributing station

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4. Main control functions of CIROS ® Advanced Mechatronics

Workpiece for MPS ® Standard systems

Workpieces Suitable for systems with

Correct intermediate product:

Housing for measuring

instrument with applied

measuring insert in different

designs

Black

Red

Metal

Fluidic Muscle Press

Storage station

Buffer station

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Workpieces Suitable for systems with

Correct workpieces: Basic

cylinder body of different types

Black

Red

Metal

Workpiece of incorrect height

and incorrectly drilled hole

Blue

Working with incorrectly drilled

hole:

Housing for measuring

instrument in different designs

Black

Red

Workpieces for MPS ® 500-FMS systems

Metal

Distributing station

Testing station

Processing station

Handling station

Quality assurance station

Sorting station

Robot assembly station

Storage station

Testing station

Processing station·

Quality assurance station

Robot assembly station

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4. Main control functions of CIROS ® Advanced Mechatronics

As soon as you create a new system, a table with the possible

workpieces is displayed as standard. If simulation is active, then select

the workpiece from this table which you want to use for the production

process of the system.

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This is how you operate an MPS ® Standard system where the

individual stations are controlled via the sample PLC programs

1. Make sure that the system is in the initial position and that there are

no workpiece on the stations. You realise this by activating the

Reset Workcell command in the Simulation menu.

2. Start simulation by clicking the Start command in the Simulation

menu.

3. The illuminated Reset button now prompts the reset function on all

stations.

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4. Carry out the reset function for each station by clicking onto the

Reset button. We recommend that you carry out the resetting of the

individual stations against the material flow.

5. The illuminated Start button of a station indicates that the

corresponding station is now in the initial position and the start

precondition is fulfilled.

6. Make sure that workpieces are available for the production process

of the system. In the case of the system shown this means that the

magazine of the distributing station must be filled with workpieces.

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Note

7. Click onto the desired workpiece on the table of workpieces. All

workpieces are realised in the form of buttons. The selected

workpiece, a red basic cylinder body, is shown as „pressed“.

Then click onto the symbolic workpiece on the distributing station.

With each mouse click the magazine is filled with the workpiece

selected.

Not every workpiece is suitable for every station. If you have selected a

workpiece which cannot be processed by a station, this workpiece

cannot not be generated for the station.

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8. Start the sequence of each station by clicking onto the Start button.

This starts the automatic mode of the station. We recommend that

you start the stations in the sequence in which they are arranged in

the material flow.

9. With the key actuator you can choose between continuous cycle

(switch position vertical) and individual cycle (switch position

horizontal) for the sequence of a station.

10. You can interrupt the sequence of a station at any time by pressing

the STOP button. If you want to restart the station, you need to carry

out the Reset function beforehand.

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Note

If a station is controlled via a PLC program you have created, then you

will know how the running and operation of the station are defined.

If a station is not controlled via a PLC program, you can selectively

trigger the process actuators manually. You will need the manual

operation window functions for this.

Slides filled with workpieces, which result in the production process

stopping, can be emptied via appropriate commands in the manual

operation window.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you operate an MPS ® 500-FMS system where the

individual stations are controlled via the sample PLC programs

The operation of an MPS ® 500-FMS system is described using the

example of a fully expanded MPS ® 500-FMS system.

1. Make sure that the system is in the initial position and that there are

no workpieces on the stations. This applies in particular to the

pallets of the transport system station, the storage slots of the

automated warehouse station and the slides of the sorting station.

Remove all workpieces by activating the Reset Workcell command

in the Simulation menu.

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2. Start the simulation by clicking the Start command in the Execute

menu.

3. The starting of simulation causes the master switch on the system to

be switched on. The master switch supplies the whole system with

power. The master switch is located on the side of the control

cabinet of the transport system station.

4. First, you start the transport system station. The flashing Automatic

On button prompts the start function. Click onto the Automatic On

button. The transport system is running and the Automatic Off

button is illuminated.

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4. Main control functions of CIROS ® Advanced Mechatronics

5. In the case of the stations at the operating positions Product Input,

Processing, Assembly and Product Output, the illuminated Reset

button prompts the reset function.

6. Carry out the reset function for the stations mentioned by clicking

onto the Reset button.

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7. In the case of the automated warehouse station it is equally

mandatory to carry out the reset function. However, for reasons

specific to this station, the reset sequence of the automated

warehouse station is different to that of the MPS ®s stations.

To reset the station, switch the AUTO/MAN key actuator into the

MAN position (switch position horizontal) by clicking onto the

AUTO/MAN key actuator. The flashing Reset button indicates that

the station can now be reset.

8. Click onto the Reset button.

The automated storage station moves into the initial position. The

axis carries out reference travel and the Start button flashes when

the initial position is reached.

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4. Main control functions of CIROS ® Advanced Mechatronics

9. Now switch the AUTO/MAN key actuator to the AUTO switching

position (switch position vertical). Automatic operation of the

station can only be started in this switching position. Start the

sequence of the station by clicking the Start button.

10. The illuminated Start button on the MPS ® stations indicates that

the corresponding stations are in the initial position and that the

start precondition is fulfilled.

11. As soon as you have filled the magazine of the distributing station

with workpieces, i.e. with basic cylinder bodies, the start

precondition for this station is also fulfilled. The Start button is

illuminated.

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12. Fill the magazine by clicking onto the desired workpiece on the

workpiece table. The selected workpiece, a red basic cylinder body,

is shown depressed.

Then click onto the symbolic workpiece on the distributing station.

With each mouse click the magazine is filled with the workpiece

selected.

13. Start the sequence of each station by clicking onto the Start button.

14. With the AUTO/MAN key actuator you can choose between

continuous cycle (switching position vertical) and individual cycle

(switching position horizontal) for the sequence of a station.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note regarding the

automated warehouse

station

Note regarding the quality

assurance station

Note

15. You can interrupt the sequence of a station at any time by pressing

the STOP button. If you want to restart the station, you need to carry

out the Reset function beforehand.

The automated warehouse station only participates actively in the

production process if product output for the process is not or is no

longer available for the process.

In concrete terms this means:

The automated warehouse stocks up if

‟ one or both stations of product output are not started or

‟ the slides at product output are full.

The automated warehouse takes out workpieces if

‟ an empty pallet passes.

The quality assurance station identifies the housing for a measuring

instrument as a reject part. The station passes on this information to the

transport system station and the transport system station passes on the

information to the robot assembly station. The robot then rejects the

transferred reject part.

If a station is controlled via a PLC program you have created, you will

know how the running and operation of the station is defined.

If the station is not controlled via a PLC, you selectively trigger the

process actuators manually. You will need the functions of the

Manual Operation window for this.

Slides filled with workpieces and which result in the production

process stopping, can be emptied using appropriate commands in

the Manual Operation window.

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This is how the status of an MPS ® system is indicated

LEDs on the sensors and valves indicate the electrical status of the

process components.

The LEDs on the inputs/outputs on the control console, provided for

the I/O connection, indicate the status of the communication

signals.

If air is applied at a cylinder connection, the connection is

highlighted in blue.

The pneumatic tubing itself is not shown.

In the windows Inputs and Outputs you can identify the status of the

PLC signals for the station selected.

The Manual Operation window provides you with an overview of all

process statuses and process activities of the system and also

displays all the communication links.

The designation of a component is shown by clicking onto the

connection or the LED of a process component. This designation is

identical to the designation in the circuit diagram.

One exception is the designations of the supply ports. These form

part of the valves which supply the supply port with air.

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Note

You can also display additional information regarding the sensors. The

settings for this are effected in model explorer.

Activate the command Model Explorer in the Modeling menu.

A tree structure is displayed.

Click onto the top entry. In the case of an MPS ® 500-FMS system,

the entry is MPS ® 500.

Now activate the context-sensitive menu via the right mouse button

and select the Properties command.

The window Properties for workcell is displayed.

Activate the Sensor Simulation register.

In the Visualisation section click onto the two check boxes for the

entries Show Measuring Range and Show Measured Value(s). Both

boxes are now shown with a tick.

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4. Main control functions of CIROS ® Advanced Mechatronics

Close the Properties for workcell window.

Close the Model Explorer window.

The respective sensor lines are now shown in the system.

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4.7

Changing the view of a

system

You can freely adjust the perspective view of a modeled system. With a

few central commands you can rotate, move, enlarge or minimize the

representation of the process model.

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4. Main control functions of CIROS ® Advanced Mechatronics

Definition of perspective view

The perspective view is defined by the coordinates of the viewer (=

standpoint) and a reference point of the process model (= mid point).

Z

Reference point

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X

Turn

Y

Angle


4. Main control functions of CIROS ® Advanced Mechatronics

This is how you move the modeled system

1. Activate the Move command in the View menu.

The mouse pointer now changes into a small coordinate system,

which indicates the direction in which the standpoint and reference

point can be moved. A dashed arrow means that it is not possible to

move into the corresponding direction.

2. Hold down the left mouse button.

3. Move the mouse pointer in the Z or X direction.

4. Release the mouse pointer again.

The view then changes accordingly.

You can also activate the Move command by holding down the Shift key

and then pressing the left mouse button.

This is how you rotate the modeled system

1. Activate the Rotate command in the View menu.

The mouse pointer changes into a small coordinate system, which

indicates the direction in which the standpoint and reference point

can be moved. A dashed arrow means that it is not possible to move

in the corresponding direction.

2. Hold down the left mouse button.

3. Move the mouse pointer in the Z or X direction.

4. Release the mouse pointer again.

The view then changes accordingly.

You can also activate the Rotate command by holding down the Ctrl key

and then pressing the left mouse button.

To tilt the system in any direction, hold down the Alt key and left mouse

button and move the mouse.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you enlarge or reduce the view

1. Activate the Zoom command in the View menu.

The mouse pointer changes into two squares.

2. If you want to enlarge the view, then hold down the left mouse

button and move the mouse pointer in the direction of the arrow.

3. If you want to reduce the view, then hold down the left mouse

button and move the mouse pointer against the direction of the

arrow.

You can also activate the Zoom command by holding down the key

combination Shift+Ctrl and then pressing the left mouse button.

If you have a mouse with a scroll wheel, you can easily enlarge or

minimise the system view by using the scroll wheel.

This is how you enlarge a specific section

1. Position the mouse pointer on a corner of the section.

2. Hold down the key combination Shift+Ctrl.

3. Press the right mouse button and move the mouse. A frame is now

displayed.

4. By moving the mouse, place the frame around the section you want

to enlarge.

5. Release the right mouse button and the section is now enlarged.

This is how you enlarge the view

Activate the Zoom-In command in the View menu. The picture is

enlarged to 125%.

This is how you reduce the view

Activate the Zoom-Out command in the View menu. The picture is now

reduced to 80%.

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4.8

The Inputs and Outputs

windows

The Inputs and Outputs windows show which signals are applied at the

inputs and outputs of the PLC for the selected station. 0 signals are

shown in red and 1 signals in green. If the input or output signal is

forced, the value is shown in angle brackets, e.g. .

The PLC inputs/outputs available for communication are designated

differently in MPS ® Standard systems and MPS ® 500-FMS systems.

In MPS ® Standard systems you will find

Panel_I4, Panel_I6, Panel_I7, Panel_Q4, Panel_Q5, Panel_Q6,

Panel_Q7

for the PLC inputs/outputs available on the control console for I/O

connection.

COMM_I0 … COMM_I7, COMM_Q0 … COMM_Q7

as additional inputs/outputs for I/O connection.

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4. Main control functions of CIROS ® Advanced Mechatronics

In MPS ® 500-FMS systems for example, PLC inputs/outputs of the

transport system station have an identifier, whereby PLC inputs/outputs

can be allocated to the individual stopper positions.

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This is how you open the Inputs window

1. Make sure that the desired system is loaded and simulation is

active.

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Note

2. Select the station whose PLC inputs you wish to observe. To do so,

click onto the Controller Selection in the Programming menu. Select

the desired PLC in the Current column via a mouse click.

The Controller Selection window displays all the stations of the

modelled system which have their own internal controller. The

controllers are switched to active by default. If system simulation is

started, for example via the Start command in the Simulation menu,

then the PLC programs of the active controllers are started in

sequence4. If system simulation is stopped, the execution of the PLC

programs in the active controllers is also stopped. The status as to

whether or not a PLC is operating is shown in the Start/Stop column.

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The status of PLC inputs/outputs is displayed in the Inputs/Outputs

window only for the controller selected as Current. Also, PLC programs

can be loaded to the selected internal controller. To do so, use for

example the Open command in the File menu.

3. Activate Inputs/Outputs in the View menu and select Show Inputs.

So that you know which process signal it is, the signal names include

the relevant designations from the circuit diagrams.

Example: STATION_1B2: The PLC input which is connected to sensor

1B2.

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This is how you open the Outputs window

1. Make sure that the desired system is loaded and simulation is

active.

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Note

2. Select the stations whose PLC you wish to observe by clicking onto

the Controller Selection command in the Programming menu.

Select the desired PLC in the Current column.

The Controller Selection window displays all the stations of the

modelled system which have their own internal controller. The

controllers are switched as active by default. If simulation of the system

is started, for example via the Start command in the Simulation menu,

the PLC programs of the active controllers are started in sequence. If

system simulation is stopped, then the execution of the PLC programs is

also stopped in the active controllers. The status as to whether or not a

PLC is operating is displayed in the Start/Stop column.

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The status of PLC inputs/outputs is displayed in the Inputs/Outputs

window only for the controller selected as Current. Also, PLC programs

can be loaded to the selected controller. To do so, use for example the

Open command in the File menu.

3. Activate Inputs/Outputs in the View menu and select Show

Outputs.

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Note

4.9

The Manual Operation

window

So that you know which process signal it is the signal names include the

relevant designation from the circuit diagrams.

Example: STATION_1M1: The PLC output which is connected to valve

coil 1M1.

It is of course possible to open the Inputs and Outputs windows at

the same time.

You can also open the Inputs and Outputs windows via Workspaces

in the Windows menu, where you will find the frequently required

window combinations.

The Manual Operation window offers various functions:

Display of the process statuses and process activities of a system,

Controlling of individual actuators of a system,

Display of communication links realised via I/O connection,

Creating of user defined communication links via I/O connection,

Setting of stops in the simulation of a system.

The entries for the individual stations of a system are configured in a

tree structure. By double clicking onto the + symbol of a station, all

entries are displayed regarding the respective station. A double click

onto the minus symbol hides the entries again.

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4. Main control functions of CIROS ® Advanced Mechatronics

The lefthand section of the window displays the process activities.

These include primarily the actuation of valves and the controlling of

communication inputs. 1 signals are indicated by a red illuminated LED.

Process activities are variables to which the process model simulation

reacts. As the user, you can change the value of this variable.

You can monitor all process activities in the righthand section of the

window.

The process statuses include status of sensors, valve coils and

communication outputs. Here, 1 signals are indicated by a green

illuminated LED.

Process statuses are variables that are set and correspondingly

displayed by the process model simulation. The user cannot change the

value of these variables.

The status of signals is also shown in the Value column. If the signal is

forced, the value is shown in angled brackets.

You can show or hide the display of the Value column. You will find the

relevant command in the context-sensitive menu via the right mouse

button.

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Additional information is also displayed: If the signal status has

changed since the last simulation cycle, the relevant line is highlighted

in colour. This enables you to easily identify and follow the signals that

have last changed. If the Value Change is not shown in colour, then

activate Show Value Changes in the context-sensitive menu via the

right mouse button.

Communication links are shown in the middle section of the window.

Communication links form part of the I/O connections.

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4. Main control functions of CIROS ® Advanced Mechatronics

The signal flow of a communication link runs from right to left. You can

see this by the orientation of the arrows at the connection ends.

You can identify the status of a communication link by the colour

marking of the connection:

Blue: Connection is selected,

Red: Connection has the value 0,

Green: Connection has the value 1.

By clicking onto an entry for which a communication link exists, the

respective communication user is also shown highlighted.

If the middle section of the window headed I/O Connections is not

displayed, then activate Show I/O Connections in the context-sensitive

menu via the right mouse button.

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Additional information

regarding the I/O

connections

I/O connections are connections between the inputs and outputs of the

system.

Differentiation should be made between

PLC inputs and outputs on the controller side,

Process inputs and outputs on the process side.

PLC outputs, for example the signal for a valve coil, are input signals for

the process.

Conversely the process generates output signals, for example sensor

signals, which are then connected to a PLC input.

These connections between PLC inputs/outputs and process

inputs/outputs also form part of the I/O connections and are required

internally by CIROS ® Advanced Mechatronics. They are taken into

account in the Manual Operation window, but are not fully displayed.

The Manual Operation window is used solely to manage the

communication links realised via I/O connection.

The table below provides an overview of the meaning of the symbols by

the entries in the window section I/O Connections.

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Process inputs

Process outputs

Important

Symbol Meaning

Not connected

Connected, but with output not displayed

Connected with displayed output

Inverted connection with one displayed

output

Forced to the value 0

Not connected

Connected, but with input not displayed

Connected with one or several displayed

outputs

You may only delete those I/O connections, which you have created

yourself as communication links. Otherwise it may no longer be

possible to simulate the system correctly.

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This is how you open the Manual Operation window

1. Make sure that the desired system is loaded. The example selected

shows an MPS Standard system, which is made up of the

distributing, testing and sorting stations.

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2. Activate Manual Operation in the Modeling menu. Alternatively,

open the window by activating Manual Operation under

Workspaces in the Windows menu.

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Note

3. Now double click the + symbol of those stations whose process

statuses and process activities you want to monitor or control.

The example shows the process statuses and process activities for

the distributing station.

You can show or hide the middle section of the Manual Operation

window headed I/O Connections as required. To do so, activate or

deactivate the Show I/O Connections command in the context-sensitive

menu via the right mouse button.

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This is how you control individual actuators of a system

If you want to manually actuate individual actuators of a system or

selectively set communication signals, we recommend that you

disconnect the respective stations of the system from their controllers.

In this way only the commands triggered via manual operation will be

executed. The PLC programs are no longer active. This procedure

prevents the output of conflicting commands to process components.

You may however also want or need to intervene manually in the

running of a station controlled via a PLC program. This enables you to

correct faulty process signals so that the sequence of a process

continues to be executed. Or you can „simulate“ communication signals

of neighbouring stations and therefore test and commission individual

PLC programs.

If you want to terminate manual operation and the respective station or

selected stations are to be controlled via the PLC programs again, then

reconnected the system with controller of the stations again.

1. Make sure that simulation is stopped.

2. Open the Manual Operation window by activating Manual

Operation in the Modeling menu.

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Note

3. Disconnect the system from the controllers.

Move the mouse pointer into the left section of the Manual

Operation window to the process activities. Press the right mouse

button to open a context-sensitive menu and select the Disconnect

All Controllers command.

You can of course also disconnect the controller from just one station.

To do so, highlight the required station in the Process Activity section of

the Manual Operation window. Then open the context-sensitive menu

via the right mouse button and select the Disconnect Selected

Controllers command.

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4. Start the simulation.

5. Double click the line of the process activity you wish to execute. The

double click causes the value of the signal to change.

If you double click a line with a valve actuation, then the value of the

corresponding valve coil changes. If the value 0 applies, this is set to

1 and vice versa. The double click therefore has a toggle function.

Please note: To switch a valve with two valve coils into a specific

switching position, the appropriate signal must be applied at both

valve coils.

6. Stop the simulation if you wish to terminate manual operation.

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Notes

7. To control the system via the PLC programs in the controllers again,

move the mouse pointer into the left section of the Manual

Operation window to the Process Activities. Open the contextsensitive

menu via the right mouse button and select the Restore

I/O Connections command.

The execution of the Reset Workcell command in the Simulation menu

also causes the inputs/outputs of the system to be reconnected to the

inputs/outputs of the controllers.

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This is how you set the stops in the operation of a system

If you want to stop the operation of a system at a defined point, then

you need to set stops within the simulation of the system. You can stop

the execution of a process whenever the value of a process signal

changes.

The stops merely influence the simulation of the system, the PLC

programs for the control of the system remain unaffected. If a stop is

applied to a signal, the system simulation stops if the signal value

changes. The changed signal value is transmitted to the system as soon

as simulation is restarted.

1. Make sure that the desired system is loaded.

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2. Start the system simulation and make sure that the system is

controlled via the PLC programs.

Open the Controller Selection window if the system is controlled via

the sample PLC programs of the individual stations. To do so, click

onto the Controller Selection command in the Programming menu.

By the symbol of the green arrowhead in the Start/Stop column you

will see that all three controllers of the system shown are operating

and the PLC programs are being executed in the controllers.

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3. Open the Manual Operation window by activating Manual

Operation in the Modeling menu.

If the window is in three parts, you can hide the middle I/O

Connections section since this section is not required when working

with stops. To hide the I/O Connections window section, deactivate

the Show I/O Connections command in the context-sensitive menu

via the right mouse button.

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4. Double click the + symbol for the-example of the distributing

station to display all the process activities of this station.

Now click onto the line of the required process activity, in the case of

this example line 2, to control the valve coil 1M1 for the ejector slide

of the magazine. Press the right mouse button to open the contextsensitive

menu and select Stop at Value Change.

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5. The stop symbol in the line in the Manual Operation window

indicates that a stop is set at this signal.

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6. Operate the process. As soon as the PLC of the distributing station

generates a 1 signal at valve coil 1M1, simulation stops. You can

follow the status of simulation at the status bar.

7. The process is continued if you restart simulation of the system. The

ejecting slide of the magazine ejects a workpiece.

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8. If you want to delete the stop, click onto the line with the stop point

with the right mouse button. Open the context-sensitive menu via

the right mouse button and select the command Stop at Value

Change. This command is realised in the form of a toggle function.

The stop is removed. Alternatively you can also select the Delete All

Stops command.

Note that you can also set stop at the signals in the Process Status

section of the window.

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This is how you control the operation of a system step by step

Use the Manual Operation window as a tool to control the simulation if

you want to execute the sequence of the process step by step. You can

stop the process at defined points by setting stops.

To execute the process step by step, set the stops at the process

activities of a station or of several stations. With this procedure the

process is stopped whenever an actuator of the respective station

changes its status. If you also want to take into consideration and

monitor communication signal during the step by step operation, then

you need to set the stops at the corresponding signals in the window

section Process Activity and Process Status.

1. Make sure that the required system is loaded. It is generally helpful

if the system is in the initial position.

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2. Start simulation of the system and make sure that the system is

controlled via PLC programs. You can establish the operational

status of the individual controllers in the Controller Selection

window.

3. Open the Manual Operation window by activating Manual

Operation in the Modeling menu.

4. If the I/O connections are displayed in the Manual Operation

window, then hide these.

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5. Double click the + symbol, for example of the distributing station, to

display all the process activities of this station.

Under Process Activity , highlight all lines which contain signals for

valve coils by pressing the Ctrl key and clicking onto the desired

lines with the left mouse button.

Open the context-sensitive menu via the right mouse button and

select Stop at Value Change.

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6. All lines with valve coils now show stops.

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7. If you also want to monitor communication, then you need to

similarly set stops at the corresponding communication signals.

In the case of MPS Standard systems, the communication exchange

takes place via optical sensors. For the distributing station only the

optical sensor IP_FI needs to be considered.

8. Operate the process using the pushbuttons and switches of the

station control consoles. The simulation stops whenever the status

of a process signal of the distributing station changes. The process

continues to be executed when you restart the simulation.

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9. Open the context-sensitive menu via the right mouse button if you

want to remove the stops again. Select the Delete All Stops entry,

doing so for both window sections.

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4.10

Controlling a system

using the internal S7 PLC

Each station is equipped with an internal PLC. A SIMATIC S7 simulator is

used as internal PLC. The S7 simulator interprets executable S7

programs.

A sample PLC program for S7-300 is available for each station. When

you load a station from the library, the sample PLC program is

automatically loaded to the internal PLC of the respective station. Once

simulation of the system is started the internal PLC executes the S

program. You can of course also download a different S7 program to the

internal PLC of a station. If doing so, you need to keep in mind the

following: Only complete project files with the file extension S7P can be

loaded. The projects must have been created with the SIMATIC Manager

and conform to the Siemens MC7 code at the binary level. This is the

case with all STEP-7 programs created in LDR, FCH, STL or GRAPH.

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This is how you control a station using a corresponding sample PLC

program

1. Load the desired MPS system. The sample selected displays an MPS

Standard system. The system is made up of the distributing, testing

and sorting stations.

2. The supplied sample PLC program for each station is loaded by

default to the corresponding internal PLC.

3. As soon as simulation of the system is started, the PLC programs of

the individual stations are also executed.

Activate Start command in the Simulation menu.

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Note

If you have modified the PLC program for a station in the corresponding

internal PLC, the modified PLC program will of course be executed once

simulation is started.

This is how you control a station using a newly created S7 PLC

program

1. Load the desired MPS station.

2. Make sure that simulation is stopped.

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3. Select the station whose PLC program you want to modify. The PLC

program is to be executed by the internal PLC.

To do so, activate the Controller Selection command in the

Programming menu. In the Controller Selection window click on to

the required station in the Currentcolumn.

4. Select the Open command in the File menu to open the Open File

window.

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5. Under file type, select S7 Project (*.S7P).

All the files of this format available in the active directory are

displayed.

6. Navigate to the directory which contains your S7 project.

Select the required S7 project and click onto Open.

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Note

7. If the project you have selected contains several S7 programs, select

the one required for the simulation and confirm this with OK.

8. Start simulation of the system. Select the Start command in the

Simulation menu. Once simulation of the system starts the PLC

programs of the individual stations are also started. The newly

loaded PLC program of the internal PLC is executed for the station

you have selected.

Another option is also available for loading PLC programs to the internal

PLC of station.

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This is how you load a PLC program to an internal PLC (alternative

method)

1. Make sure that the desired MPS system is loaded.

2. Make sure that simulation is stopped.

3. Open the S7 Program Manager by activating the S7 Program

Manager command in the Programming menu.

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4. The just loaded PLC program for each internal PLC is shown in a

clearly set out tree structure.

Click onto the + symbol in front of the station whose PLC program

you want to change. In the exampIe the testing station has been

selected. Highlight the Program entry.

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5. Open the context-sensitive menu via the right mouse button and

select the Load command.

6. The Open window is now displayed.

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7. Navigate to the directory which contains your S7 project.

Select the desired S7 project and click onto the Open button.

8. If the project you have selected contains several S7 programs, select

the one required for simulation. Confirm your selection with OK.

The required PLC program is loaded. You can now simulate the

operation of the system.

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This is how you establish which S7 program in the internal PLC of a

station has just been loaded

1. Make sure that the desired MPS system is loaded.

2. Activate the S7 Program Manager command in the Programming

menu.

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3. A clearly set out tree structure shows the just loaded PLC program

for each internal PLC.

4. Click onto the + symbol to display the name and structure of the PLC

program.

The PLC program can consist of the following modules: Organisation

modules, data modules, functions and system functions.

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5. Click onto the + symbol again to display the modules of the PLC

programs.

You can view the contents of the module by double clicking onto a

module.

Further information regarding the display of S7 programs in STL or the

display and use of timing diagrams can be found in the online Help.

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This is how the sample PLC programs are filed on the computer

1. Select the Open command in the File menu. The Open File window is

now displayed.

2. Select S7 Project (*.S7P) under file type.

All the files of this format available in the active directory are

displayed.

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3. Navigate into the directory in which you have installed the Software

package CIROS ® Advanced Mechatronics software package. From

there change to the directory \CIROS ® Advanced

Mechatronics\bin\FD_PLC_ADV\S7 where four subdirectories are

shown.

‟ The directory MPSC_V22 contains the S7 project mpsc_v22.s7p,

where you will find the sample PLC programs for all MPS

Standard stations.

‟ The directory FMS50__1 contains the sample PLC programs for

the transport system of MPS 500-FMS systems.

‟ The directory 313C__1 contains the sample PLC programs for the

individual stations of MPS 500-FMS systems.

‟ The directory Store contains the sample PLC programs for the

automated warehouse station.

4. As an example, change to the directory MPSC_V22. Select the

S7 project and click onto Open.

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The program name provides information about the PLC program and the

station model to which it belongs:

The initial digit corresponds to the station number.

The two letters after the first digit indicate the station:

VE: Distributing station

PR: Testing station

BE: Processing station

HA: Handling station

PU: Buffer station

MO: Assembly station

SO: Sorting station

PP: Pick&Place station

FM: Fluidic Muscle Press station

TR: Separating station

LA: Storage station

The letters starting with underscore indicate the programming

language of the PLC program:

AS: The programming language GRAPH,

KFA: The programming languages LDR, FCH and STL,

The internal PLC supports to a large extent the command set of the S7-

400 controllers, whereby the programs can be created in ladder

diagram, function chart, statement list or in the form of graphic

sequence control.

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Note

4.11

Controlling a system

station using the external

Soft PLC S7-PLCSIM

Note

5. Close the window by clicking on the Cancel button.

You must never modify the sample PLC programs shown here because

these are the standard default programs required for the simulation of

an MPS system.

If you want to make changes to the PLC programs, then install these a

second time using the specially provided installation command of

CIROS ® Advanced Mechatronics Assistant.

S7-PLCSIM is a soft PLC, which executes the PLC programs created in

STEP 7. A wide range of different testing and diagnostic functions for

fault finding in the PLC program are available within STEP 7. These

testing and diagnostic functions include for example the status display

of variables or the online display of the PLC program. You can use these

functions if you create the PLC program for a station of a system in

STEP-7 and then test the PLC program in conjunction with the

simulation of the system.

The exchange of PLC input/output signals between the system and the

soft PLC S7-PLCSIM is effected via the EzOPC program. The EzOPC

program forms part of the CIROS ® Automation Suite and has been

installed on your PC together with the CIROS ® Advanced Mechatronics

application.

EzOPC is automatically invoked by CIROS ® Advanced Mechatronics as

soon as you start simulation of the system. The prerequisite for starting

EzOPC is of course that at least one station of the system is controlled

via an external PLC.

If you work with the operating system Vista, please make sure that the

used S7-PLCSIM-Version is Vista compatible.

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Configuration of EzOPC for data exchange with S7-PLCSIM

To ensure that the exchange of PLC input/output signals with the

selected station is correctly effected, the following requirements must

be met:

When starting EzOPC, both communication users – S7-PLCSIM and

simulation of the system – must be active. Only then can EzOPC set

up the communication link to both users.

The EzOPC program must be correctly configured for the exchange of

data. Therefore check the configuration as soon as EzOPC is started.

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This is how you control a station of the virtual system using S7-

PLCSIM

1. Start STEP 7 or then STEP 7 Manager and open the desired S7

project.

2. Start S7-PLCSIM by clicking onto the menu item Simulate Modules

under Extras.

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3. The window of S7-PLCSIM is opened.

Enter the input/output bytes you want to exchange and monitor.

4. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto

MRES in the CPU window.

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5. Download the required PLC program to the S7-PLCSIM by

highlighting the modules folder. Then activate the Download

command in the PLC menu.

The PLC program is to control a selected station in a virtual MPS

system in CIROS ® Advanced Mechatronics. The selected station to

be controlled via S7-PLCSIM is the distributing station.

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6. Load the appropriate MPS system in CIROS ® Advanced

Mechatronics.

7. Make the necessary setting for the desired station, i.e. that this is to

be controlled via an external PLC by activating the Switch external

PLC internal PLC command in the Modeling menu.

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8. The Switch external PLC internal PLC window is now opened.

The columns Type and Program Name/OPC Server show the

information for the controller of the selected station.

As an example consider the entries for the distributing station:

‟ The name of the station is Distributing.

‟ The station is controlled via the internal PLC. You can establish

this by the S7 PLC simulator entry.

‟ The internal PLC executes a PLC program, which is part of the

STEP 7 project MPSC_V22.S7P with specified path.

9. Highlight the desired station via mouse click. Activate the contextsensitive

menu via the right mouse button and select the Switch

command.

Alternatively changeover the controller by double clicking the

desired station.

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10. For the selected station OPC server is now entered in the Type

column. The name FestoDidactic.EzOPC.2 is now displayed under

program name/OPC server. This entry means the process signals for

the selected station are exchanged via an OPC server named

FestoDidactic.EzOPC.2.

11. Close the Switch external PLC internal PLC window.

12. Check whether the system should be in the initial position. If so,

activate Reset Workcell command in the Simulation menu.

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13. Start simulation of the system by activating Start in the Simulation

menu.

When simulation is started the EzOPC progam is automatically

invoked. You can establish this by the EzOPC entry in the bar.

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Note

With the starting of system simulation, the communication program

EzOPC is also started. When EzOPC is started, both communication

users - S7-PLCSIM and the simulation of the system – must already be

active. Only then are the communication links correctly set up.

14. Click onto EzOPC in the start bar. The EzOPC window is now

displayed, where you configure the communication between CIROS ®

Advanced Mechatronics and S7-PLCSIM.

The overview indicates that CIROS ® Advanced Mechatronics is

connected to

S7 PLCSim via the virtual controller of EzOPC. The table shows which

components are installed individually and whether EzOPC is in the

process of accessing this component.

Make sure that the communication links of your EzOPC are

configured as shown below. The desired communication links are

established by clicking onto the appropriate button.

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15. Now click onto the Virtual Controller register where the virtual

controller status and your inputs/outputs are displayed. 8 input

bytes and 8 output bytes are preset for data exchange. You can

accept this presetting unaltered.

If a 1-signal is applied to an input/output byte bit, then this is shown

illuminated.

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16. Click onto the S7-PLCSIM register and check the settings. Here, the

status of S7-PLCSim simulation and its inputs/outputs is displayed.

8 input bytes and 8 output bytes are preset for data exchange. You

can accept this presetting unaltered. However, only the first 4 bytes

are required.

If a 1-signal is applied to an input/output byte bit, then this is shown

illuminated.

17. Minimise the EzOPC window.

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18. Start S7-PLCSIM by clicking onto the check box next to RUN in the

CPU window. The LED for RUN should now start flashing.

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19. Operate the system. In particular, observe the behaviour of those

stations for which you have created the PLC program yourself. It can

be useful here to monitor the statuses of the PLC inputs and outputs

for the respective station.

Open the Inputs and Outputs window by activating the commands

Show Inputs or Show Outputs under the Inputs/Outputs entry in

the View menu.

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20. Make sure that the PLC inputs and outputs for the right station are

displayed by activating the Controller Selection command in the

Programming menu. Select the controller for the desired station in

the Current column. For the example this should be the distributing

station.

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21. If errors still exist in the PLC program, then the online representation

in STEP 7 provides excellent support during fault finding. To do so,

call up the program module in which you suspect the fault. Activate

the Monitor command in the Test menu. You can now monitor which

PLC program sections are executed or not in parallel with the

simulation of the process.

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4.12

Controlling a station of

the system using the

external Soft PLC

CoDeSys SP PLCWinNT

Note

CoDeSys SP PLCWinNT is a Soft PLC which executes the PLC programs

created in CoDeSys.

The PLC input and output signals are exchanged between the system

simulation and the Soft PLC CoDeSys SP PLCWinNT via the EzOPC

program. EzOPC is part of the CIROS ® Automation Suite, and will have

been installed on your PC together with the CIROS ® Advanced

Mechatronics application.

CIROS ® Advanced Mechatronics automatically starts up EzOPC as soon

as the simulation of the system begins. Of course, at least one station of

the system must be under the control of an external PLC before EzOPC

can be started.

If you are using the MS Windows Vista operating system, ensure that

the version of CoDeSys SP PLCWinNT which you are using is Vistacompatible.

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4. Main control functions of CIROS ® Advanced Mechatronics

The following requirements must be fulfilled in order to ensure that the

PLC input and output signals are exchanged correctly with the selected

station:

There must be an interface to the OPC server EzOPC in the CoDeSys

PLC program. The input and output signals of the PLC program are

transferred byte by byte via this interface.

The UNPACK functional module and the PACK function in CoDeSys

can be used to convert bits to bytes.

Program execution in CoDeSys SP PLCWinNT

UNPACK (FB)

PLC program

PACK (FUN)

EB0

B B0

B1

B2

B3

B4

B5

B6

B7

OPC_notUsed

OPC_1B2

OPC_notUsed

OPC_2B1

OPC_3B1

OPC_notUsed

OPC_notUsed

OPC_notUsed

OPC_1B2

OPC_2B1

OPC_3B1

& OPC_P2

OPC_notUsed

OPC_P2

OPC_notUsed

OPC_notUsed

OPC_notUsed

OPC_notUsed

OPC_notUsed

OPC_notUsed

B0

B1

B2

B3

B4

B5

B6

B7

PACK

AB1

Process inputs

(Sensors)

CIROS

EzOPC

®

Process model

simulation

Simple program example of OPC interface in CoDeSys

Process outputs

(Actors)

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4. Main control functions of CIROS ® Advanced Mechatronics

Configuration of EzOPC for data exchange with S7-PLCSIM

When starting EzOPC, both communication users – CoDeSys SP

PLCWinNT and the system simulation in CIROS – must already be

active. Only then can EzOPC set up the communication link to both

users.

The EzOPC program must be correctly configured for data exchange.

In order to ensure this, check the configuration as soon as EzOPC

starts up.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you control a station of the virtual system with

CoDeSys SP PLCWinNT

1. Start CoDeSys and open the desired CoDeSys project.

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4. Main control functions of CIROS ® Advanced Mechatronics

2. Make sure that the Util.lib library is entered in the Resources tab.

If this is not the case, add the Util.lib library using the Library

Manager: Double-click on Library Manager in the Resources tab. In

the Insert menu, select Additional Library. Find the location where

Util.lib is stored. The default location for the library is in the

directory c:\Program Files\3S Software\CoDeSys\Library.

Once you have selected the Util.lib library, click on the Open button.

Close the Library Manager window.

3. Next, define the input/output signals to be exchanged with the

CIROS ® process model via the OPC interface. The input/output

signals in the example project can be easily identified by the

extension OPC. The input/output signals are defined as global

variables.

You can open the Global_Variables window by opening the Global

Variables folder in the Resources tab, then double-clicking on

Global_Variables.

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4. Main control functions of CIROS ® Advanced Mechatronics

4. Expand the control program by calling up the UNPACK functional

module. This extracts the EB0 input byte and converts it into

8 Boolean variables. In the example project, only bits 1, 3 and 4 of

the EB0 input byte are needed.

Remember that an instance (Unpack_EB0 in the example) must be

defined in the program head before a functional module can be

called up.

5. Expand the control program by calling up the PACK function. The

PACK function combines 8 Boolean variables into one byte. In the

example, the PACK function shows the output signal OPC_P2 on bit

1 of output byte AB1.

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4. Main control functions of CIROS ® Advanced Mechatronics

6. Make sure that the Soft PLC CoDeSys SP PLCWinNT is set as the

target system for the project. To do this, double-click on Target

Settings in the Resources tab. 3S CoDeSys SP PLCWinNT must be

set as the configuration.

7. Next, configure the settings in CoDeSys for the data exchange

between CoDeSys SP PLCWinNT and CIROS ® Advanced

Mechatronics. To do this, open the Start menu, go to

3S Software -> Communication and select CoDeSys OPC

Configurator.

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4. Main control functions of CIROS ® Advanced Mechatronics

8. Set Single PLC for OPC communication. Do this by selecting Single

PLC in the File menu.

9. In the tree structure, click on Server and set an Update Rate of 100

for the OPC server. Alternatively, you can also use the preset value.

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4. Main control functions of CIROS ® Advanced Mechatronics

10. In the tree structure, click on PLC and enter the name of the PLC

project.

Note

The project name must exactly match the name of the CoDeSys

project file. If the project is changed, the name must also be

changed here to match.

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4. Main control functions of CIROS ® Advanced Mechatronics

11. In the tree structure, click on Connection to specify the type of

connection between the OPC server and the Soft PLC. As both

programs run on the same computer, select the Local option for

Gateway. Select Tcp/lp with the Address localhost as the Device for

the new connection.

Configure the settings in the Communication Parameters window.

12. Open the Communication Parameters window by clicking on the

Edit button. Then click on the Gateway button and select Local as

the connection for Gateway.

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4. Main control functions of CIROS ® Advanced Mechatronics

13. Click the New button to define the parameters for the new

connection channel. Enter the name of the channel and select

Tcp/lp as the device.

14. Close the window Communication Parameters: New Channel.

15. Close the windows Communication Parameters and OPCConfig.

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4. Main control functions of CIROS ® Advanced Mechatronics

16. Next, prepare the input/output bytes which are to be transferred via

the OPC interface for data exchange. To do this, activate the Options

command in the Project menu in CoDeSys. In the Options window,

click on Symbol configuration.

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4. Main control functions of CIROS ® Advanced Mechatronics

17. Select Dump symbol entries, then click on the configure symbol file

button.

This opens the Set object attributes window.

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4. Main control functions of CIROS ® Advanced Mechatronics

18. Open the Global Variables folder and select the objects AB1 (BYTE)

and EB0 (BYTE). Hold down the Ctrl key while selecting.

Place a tick in each check box and close the Set object attributes

and Options windows.

19. Click on the Rebuild all command in the Project menu.

20. Start CoDeSys SP PLCWinNT by selecting it from the Start menu.

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4. Main control functions of CIROS ® Advanced Mechatronics

21. The CoDeSys SP PLCWinNT window opens.

22. To establish the connection between the CoDeSys programming

system and the Soft PLC CoDeSys SP PLCWinNT, activate the Login

command in the Online menu in CoDeSys.

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4. Main control functions of CIROS ® Advanced Mechatronics

23. If the current project is different to the PLC program in the Soft PLC,

you will be asked whether you wish to load the current PLC program

when you log in. Click Yes.

The current project is loaded into the Soft PLC.

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4. Main control functions of CIROS ® Advanced Mechatronics

24. Load the corresponding MPS in CIROS ® Mechatronics.

25. Alter the settings for the desired station so it is controlled by an

external PLC. To do this, go to the Modeling menu and activate the

Switch external PLC internal PLC command.

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4. Main control functions of CIROS ® Advanced Mechatronics

26. The Switch external PLC internal PLC window opens.

The Type and Program Name/OPC Server columns show

information on how the selected station is controlled.

For example, take a look at the entries for the Distributing station:

‟ The name of the station is S7_Distributing.

‟ The station is controlled by the internal PLC. You can see this

from the S7 PLC Simulator entry in the Type column.

‟ The internal PLC executes a PLC program. The PLC program is

part of the STEP 7 project MPSC_V22.S7P with the specified

path.

27. Click on the desired station to highlight it. Click the right mouse

mutton to open the context-sensitive menu. Select the Switch

command.

Alternatively, you can switch the control system by double-clicking

on the desired station.

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4. Main control functions of CIROS ® Advanced Mechatronics

28. The column Type now shows OPC Server for the selected station.

The Program Name/OPC Server column now shows the server name

FestoDidactic.EzOPC.2. This means that the process signals for the

selected station are exchanged via an OPC server with the name

FestoDidactic.EzOPC.2.

29. Close the Switch external PLC internal PLC window.

30. Check whether the system is meant to be in the basic setting. If so,

activate the Reset Workcell order in the Simulation menu.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

31. Start the simulation of the system. To do this, open the Simulation

menu and select Start.

As the simulation starts, the EzOPC program is automatically

opened. You can see this because EzOPC appears in the start bar.

When the system simulation starts, the EzOPC communication program

also starts up. When starting EzOPC, both communication users –

CoDeSys SP PLCWinNT and the system simulation – must already be

active. Only if this is the case will the communication links be correctly

set up.

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4. Main control functions of CIROS ® Advanced Mechatronics

32. Click on the EzOPC button in the Start bar. The EzOPC window

opens. Here you can configure the communication between CIROS ®

Advanced Mechatronics and CoDeSys SP PLCWinNT.

The overview shows that CIROS ® Advanced Mechatronics is

connected to CoDeSys SP PLCWinNT via the EzOPC virtual control

system. The table shows details of which components are installed

whether EzOPC directly accesses these components.

Make sure that the communication links of your EzOPC are

configured as shown below. You can create the desired

communication link by clicking the corresponding button.

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4. Main control functions of CIROS ® Advanced Mechatronics

33. Next, click on the Virtual Controller tab. This displays the status of

the virtual controller and its I/Os. 8 input bytes and 8 output bytes

are preset for data exchange. You can use this preset without

modifying it.

If logic 1 applies to any bit of the input/output byte, this bit is

represented by a brighter colour.

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4. Main control functions of CIROS ® Advanced Mechatronics

34. Click on the CoDeSys tab and check the settings. This tab shows the

status of the CoDeSys SP PLCWinNT simulation and its inputs/

outputs. 8 input bytes and 8 output bytes are preset for data

exchange. You can use this preset without modifying it. However,

only the first 4 bytes are required.

If logic 1 applies to any bit of the input/output byte, this bit is

represented by a brighter colour.

35. Minimise the EzOPC window.

36. Make sure that the process model simulation is active in CIROS ®

Advanced Mechatronics.

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4. Main control functions of CIROS ® Advanced Mechatronics

37. Start running the PLC program in the Soft PLC. To do this, open the

Online menu and click Run.

You can see the current status of the Soft PLC CoDeSys SP PLCWinNT

in the CoDeSys SP PLCWinNT window.

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4. Main control functions of CIROS ® Advanced Mechatronics

38. Operate the system. Pay particular attention to the behaviour of the

station to which you have added the PLC program yourself. You

might find it helpful to follow the statuses of the PLC inputs and

outputs for the station in question.

To open the Inputs and Outputs windows, go to the View menu,

select Inputs/Outputs and activate the Show Inputs and

Show Outputs commands.

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4. Main control functions of CIROS ® Advanced Mechatronics

39. Make sure that the PLC inputs and outputs are shown to the right

station. To do this, go to the Programming menu and activate the

Controller selection command. Select the control system for the

desired station in the Current column. In the example, this would be

the Distributing station.

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4. Main control functions of CIROS ® Advanced Mechatronics

4.13

Controlling a station of

the system using an

external PLC

If you are creating and testing your own PLC programs we recommend

that you load the programs to an external PLC and execute them from

there.

If you are programming in STEP 7, you can use the soft PLC S7-PLCSIM

as PLC, in which case you will not require any additional hardware

components.

You can however also use any other control and programming system,

in which case you load the PLC program to your hardware PLC. The PLC

program is to control a selected station of your virtual system.

The exchange of PLC input/output signals between the system

simulation and your external PLC is effected via the serial or the USB

interface of the PC and via the EasyPort interface. In addition the EzOPC

program is involved in the exchange of process signals.

The advantage of this configuration is that you can use the PLC and the

programming system of your choice. Also the testing and diagnostic

functions provided by the programming system for this purpose are

available to you for fault finding in the PLC program.

We recommend that you install the simulation software CIROS ®

Advanced Mechatronics and the PLC programming system on different

computers.

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4. Main control functions of CIROS ® Advanced Mechatronics

Station of a system

EasyPort

PLC

Possible configuration with hardware PLC and two PCs

PLC programming system STEP7

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

The EzOPC program

You can however also select another configuration and install the two

software packages on one PC. Your PC needs to be equipped with two

serial interfaces or one serial and one USB interfaces if you want to use

the testing and diagnostic functions of the programming system during

simulation of the virtual system.

You can use the following as EasyPort interface:

EasyPort D16 interface box for 16 digital I/O (Pt. No. 167121)

The following is required as data cable:

PC data cable RS232 for EasyPort with PC to RS232 (Order No.

162305) or

USB adapter RS232 for EasyPort with PC on USB (Order No. 540699)

For PLC EduTrainer from Festo Didactic: I/O data cable with SysLink

connectors to IEEE 488 at both ends (Pt. No. 034 031) and adapter

for extension to IEEE 488, crossover (Pt. No. 167 197)

For any PLC: I/O data cable with SysLink connector to IEEE 488 at

one end and open cable end sleeves (Pt. No. 167 122)

If you want to exchange signals of one or more than 16 process

inputs/outputs between an external PLC and a virtual system in CIROS ®

Advanced Mechatronics, you will need two or more EasyPort interfaces.

The EzOPC program organises the exchange of PLC input/output signals

between the virtual system simulation and the external PLC. EzOPC

does not access the signals of the external PLC directly but via the

EasyPort interface.

The EzOPC program forms part of the CIROS ® Automation Suite and has

been installed on your PC in conjunction with the CIROS ® Advanced

Mechatronics application. EzOPC is automatically invoked by CIROS ®

Advanced Mechatronics as soon as simulation of the system starts.

Prerequisite for starting EzOPC is of course that at least one station of

the system is controlled via an external PLC.

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4. Main control functions of CIROS ® Advanced Mechatronics

The following requirements must be fulfilled to ensure that the

exchange of PLC input/output signals with the selected station is

correct:

When starting EzOPC, both communication users ‟ EasyPort and

simulation of the system ‟ must be active. Only then can EzOPC set

up the communication link with the two users.

In the case of EasyPort this means that EasyPort must be connected

to the PC via the serial or the USB interface and voltage must be

applied to EasyPort.

The EzOPC must be correctly configured for the exchange of data.

Therefore check the configuration as soon as EzOPC is started.

Configuration of EzOPC for data exchange with an external PLC via EasyPort

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you control a station of a virtual system using an external

PLC

1. Load the desired PLC program to the external PLC. The external PLC

is in the STOP operating status.

2. Connect the PC with CIROS ® Advanced Mechatronics to the external

PLC via the EasyPort interface.

‟ The data cable Pt. No. 162 305 connects the serial interface of

the PC to the serial interface RS232 of EasyPort.

If you are using the USB interface, then use the data cable of

Order No. 540699.

‟ The PLC input output signals for the process are applied at port 1

of EasyPort.

‟ The PLC input/output signals for the control console are

transmitted via port 2.

‟ If you are using EasyPort without USB interface:

Select the following setting for the DIP switches under Mode on

EasyPort:

1 ON (bottom), 2 OFF, 3 OFF.

‟ If you are using EasyPort with USB interface:

Make sure that address 1 is set for EasyPort.

The set address can be read or changed by pressing the two

arrow buttons. Simultaneously pressing both buttons stores the

address and exits address mode.

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4. Main control functions of CIROS ® Advanced Mechatronics

S7 EduTrainer EasyPort

CPU313C-2 DP

SF

BF 0

0

DC5V

FRCE 2

2

RUN 3

3

STOP 4

4

PUSH

5

5

RUN

STOP

MRES

6

7

IN

0

2

3

4

5

6

7

6

7

OUT

0

2

3

4

5

6

7

CP 343-2

Configuration with PLC EduTrainer

Note

1

1

1

1

SF

PWR

APF

CER

AUP

CM

B

20+

10+

SET

9

8

7

6

5

4

3

2

1

0

1 3

A

B

Process model

RING IN OUT MODE RS232 - 24V +

STATUS SHORT

246

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INPUT

EasyPort D16

OUTPUT

0 7 8

15

PORT 1 PORT 2

1 2 3

The two sockets marked EMERGENCY-STOP must be bridged so that the

output modules of the PLC receive the voltage supply.

ON


4. Main control functions of CIROS ® Advanced Mechatronics

PLC board

Configuration with PLC board

Process model

EasyPort

RING IN OUT MODE RS232 - 24V +

STATUS SHORT

XMA2 XMG1

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INPUT

EasyPort D16

OUTPUT

0 7 8

15

PORT 1 PORT 2

1 2 3

ON


4. Main control functions of CIROS ® Advanced Mechatronics

3. Switch on the voltage supply of EasyPort. Note that EasyPort can

receive voltage supply via the PORTS.

4. Load the desired system in CIROS ® Advanced Mechatronics. One

station of the system is to be controlled via an external PLC. The

distributing station has been selected in the example.

5. Effect the setting for the required station which is to be controlled

via an external PLC by activating the Switch external PLC internal

PLC command in the Modeling menu.

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4. Main control functions of CIROS ® Advanced Mechatronics

6. This opens the Switch external PLC internal PLC window.

The controller for the selected station is shown in the columns Type

and Program name/OPC Server.

As an example take a look at the entries for the distributing station:

‟ The name of the station is Distributing.

‟ The station is controlled via the internal PLC. You can establish

this by the entry S7 SPS Simulator.

‟ The internal PLC executes the PLC program. The PLC program

forms part of the STEP 7 project MPSC_V22.S7P with the path

indicated.

7. Highlight the required station via a mouse click. Activate the context

sensitive menu via the right mouse button and select the Switch

command.

Alternatively changeover the controller by clicking onto the required

station.

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4. Main control functions of CIROS ® Advanced Mechatronics

8. OPC Server is entered for the selected station in the Type column.

FestoDidactic.EzOPC.2 is shown under Program name/OPC Server.

This means that the process signals for the selected station are

exchanged via an OPC server named FestoDidactic.EzOPC.2.

9. Close the Switch external PLC internal PLC window.

10. Check whether the system is to be in the initial position. If so,

activate the Reset Workcell command in the Simulation menu.

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4. Main control functions of CIROS ® Advanced Mechatronics

11. Start the system simulation by activating Start in the Simulation

menu.

With the starting of simulation, the EzOPC program is automatically

invoked. You can establish this by the EzOPC entry in the start bar.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

With system simulation starting, the communication program EzOPC is

also started. When EzOPC is started, both communication users –

EasyPort and the simulation of the system – must already be active.

Only then are the communication links correctly set up.

12. Click onto EzOPC in the start bar to open the EzOPC window. Here

you configure the communication between H CIROS ® Advanced

Mechatronics and EasyPort.

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4. Main control functions of CIROS ® Advanced Mechatronics

13. The overview shows that CIROS ® Advanced Mechatronics is

connected to S7 PLCSim via the virtual controller of EzOPC.

You will need a communication link between CIROS ® Advanced

Mechatronics and EasyPort. Click onto the PLC via EasyPort button

to establish this.

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4. Main control functions of CIROS ® Advanced Mechatronics

14. The configuration link between CIROS ® Advanced Mechatronics and

EasyPort is configured.

The table indicates which components are installed and whether

EzOPC is currently accessing these components.

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4. Main control functions of CIROS ® Advanced Mechatronics

15. Now check the range of inputs/outputs via which data exchange is

to be effected in the virtual controller. To do so, click onto the

Virtual Controller register.

8 input bytes and 8 output bytes are preset for data exchange. You

can accept these presettings unaltered. Only the first 4 bytes are

required.

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4. Main control functions of CIROS ® Advanced Mechatronics

16. Click onto the EasyPort register where the status of the connected

EasyPort and its inputs and outputs are displayed. If a 1-signal is

applied to an input/output byte bit, then this is shown illuminated.

17. Minimise the EzOPC window.

18. Make sure that the required PLC program is installed in the PLC.

19. Start the PLC.

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4. Main control functions of CIROS ® Advanced Mechatronics

20. Operate the system and in particular observe the behaviour of the

station for which you have created the PLC program, whereby it may

be helpful to observe the statuses of the PLC inputs and outputs of

the relevant station. Open the inputs and outputs window by

activating the Show Inputs/Show Outputs command under the

Inputs/Outputs entry in the View menu.

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4. Main control functions of CIROS ® Advanced Mechatronics

21. Make sure that the PLC inputs and outputs for the right station are

displayed. Activate the Controller Selection command in the

Programming menu and select the controller for the desired station.

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4. Main control functions of CIROS ® Advanced Mechatronics

4.14

Setting faults in a system

Use the Fault Setting window to set specific faults in the functional

sequence of a system. Use the internal S7 PLC and the sample PLC

programs provided to control the system. This ensures that any

potential process malfunction is caused solely by the process

components. The PLC programs operate error-free.

The setting of faults is permissible for authorised persons only and the

dialog for the setting of faults is therefore password protected.

The default setting for the password is didactic. This password can be

changed at any time.

A list of possible faults is available for each modelled system. The

entries for the individual stations are arranged in a tree structure. All

entries for the relevant station are displayed by double clicking onto the

+ symbol of a station. To hide the entries again double click the minus

symbol.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

The following data is required if you want to create a fault in the case of

one of the listed process components:

Type of fault,

Start of malfunction,

Duration of malfunction.

Various faults can occur in the case of some components. You can select

these in a selection list.

The following denote:

Reed switch misaligned: Reed switch is mechanically misaligned.

Reed switch stuck: A 1 signal is permanently applied at the reed

switch.

Cable break: A 0 signal is permanently applied at the component.

Short circuit: A 1 signal is permanently applied at the component.

Failure: Complete component failure.

Tubing faulty: Pneumatic tubing is defective, operating pressure is

not achieved.

Compressed air line faulty: No compressed air available.

Voltage supply malfunctioning: No voltage.

The time specified for the commencement of malfunction refers to the

simulation period after the fault is set.

The duration of malfunction is to be specified in seconds.

The error statuses are effected in the simulation of the modelled system

as soon as the fault simulation is active.

If you exit and restart CIROS ® Advanced Mechatronics, malfunction still

remains active and remains active until it is deactivated in the Fault

Setting window.

Default malfunction however only becomes active if the fault simulation

mode is activated.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you set faults in a modelled system

1. Make sure that the system is loaded. The system is to be controlled

via the internal PLC. Simulation is not active.

2. Open the Fault Setting window by activating the Fault Setting entry

in the Extras menu under Fault Simulation.

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4. Main control functions of CIROS ® Advanced Mechatronics

3. The dialog for the password entry is now displayed.

Enter the password. Provided that you have not changed the

password since installing CIROS ® Advanced Mechatronics, the set

default password is still valid.

Under password, enter didactic

Please note that the above password is case sensitive.

Confirm the entry with OK.

4. The Fault Setting window now opens.

5. Double click the + symbol of for example the distributing station to

display all the possible faults of this station.

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4. Main control functions of CIROS ® Advanced Mechatronics

6. Now set a malfunction ‟ for example for the PLC input 1B1.

Double click the appropriate field in the Type column. A selection list

is displayed. Open this list and select the type of fault, for example

cable break.

The fault is to become active at the start of simulation and remain

active until the fault is removed from the fault setting. No entries are

therefore required in the Begin column.

The duration of the fault is arbitrary. No entries are therefore

required in the Duration column.

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4. Main control functions of CIROS ® Advanced Mechatronics

7. The faults selected are displayed in the Status column.

8. Close the file of the modelled system in order to deactivate the

teacher mode.

9. Load the system with the set faults.

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10. Now activate the fault simulation mode by selecting Fault

Simulation in the Extras menu under Fault Simulation.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you start simulation of the system with set faults

1. Load the system with the set faults.

2. Make sure that the fault simulation mode is activated. The menu

item Fault Simulation in the Extras menu under Fault Simulation

must be ticked.

3. Start simulation of the system.

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4. Main control functions of CIROS ® Advanced Mechatronics

4.15

Eliminating faults in a

system

Example

Use the Fault Localisation window to eliminate malfunction in the

functional sequence of the system. Set malfunction only occurs if the

system is controlled via PLC programs and if the fault simulation mode

is active.

The MPS system viewed consists of the distributing, testing and sorting

stations. The sequence of the system stops once a workpiece is ejected

at the distributing station. The next step - moving the swivel arm into

the magazine position - is not executed.

By observing and evaluating the system, you realise that voltage is

applied at sensor 1B1 of the distributing station, but not at the

corresponding PLC input. You therefore conclude a cable break at the

PLC input 1B1.

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4. Main control functions of CIROS ® Advanced Mechatronics

This is how you eliminate faults in the system

1. Make sure that the desired system is loaded.

2. Open the Fault Localisation window by clicking onto Fault

Localisation in the Execute menu.

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4. Main control functions of CIROS ® Advanced Mechatronics

3. The Fault Localisation window is now displayed.

4. Double click the + symbol of the distributing station to view all

possible faults.

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4. Main control functions of CIROS ® Advanced Mechatronics

5. Double click no fault in the line PLC input 1B1 and select cable

break from the selection list.

The button is illuminated in yellow.

If the fault has been identified correctly, the distributing station

sequence will be executed error-free in the next simulation cycle.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

6. In the teacher mode, the Fault Localisation window is displayed as

follows:

If you have correctly identified and entered the fault, the sequence

of the system will be executed error-free in the next simulation cycle.

If the cause of the fault has not been identified correctly, the fault

will continue to exist.

If you have erroneously identified and entered the cause of the fault

as a mechanically misaligned sensor, you have created an additional

fault in the process. The fault is active as of the next simulation

cycle.

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4. Main control functions of CIROS ® Advanced Mechatronics

4.16

Logging error elimination

Each action in the Fault Localisation window is recorded in a log file.

Authorised persons have the option of viewing the log file.

The log file contains a list of activities carried out in the fault localisation

window. The entries contain the following data

Date

Time

Correctly identified and eliminated faults are highlighted in green.

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4. Main control functions of CIROS ® Advanced Mechatronics

Note

This is how you view the log file

1. Open the fault log window by activating the Fault Log entry in the

Extras menu under Fault Simulation.

2. The dialog box for the password entry is now displayed.

Enter the password. The preset default password is still valid,

provided that you have not changed this since installing CIROS ®

Advanced Mechatronics.

Enter didactic under password.

Note that the password is case sensitive.

Confirm your entry with OK.

3. The Fault Log window is now displayed.

If you want to delete the fault log, activate the context-sensitive menu

via the right mouse button and select the appropriate command.

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5. These training contents can be taught using

CIROS ® Advanced Mechatronics

5.1

Training contents and

training aims

Main training aims

CIROS ® Advanced Mechatronics is a multimedia training aid dealing

with the subject of automated systems. The examples used relate to

practical applications in industry and the problem definitions are based

on industrial handling sequences and are aimed at a holistic training

process. With CIROS ® Advanced Mechatronics you are imparting

methodological and handling competence.

CIROS ® Advanced Mechatronics provides process models for different,

complex sections of production systems.

The general training aims of CIROS ® Advanced Mechatronics are to

achieve the following skills

To design and construct PLC controlled systems in the form of

distributed systems,

To specify, design and test communication between the intelligent

stations of a distributed system,

To create, modify and test the PLC programs for the individual

stations of a distributed system or complete system,

To carry out systematic fault finding as part of servicing and

maintenance of distributed systems.

This training aim deals with all the topics which can be addressed by

means of simulated processes of distributed systems. The main focus of

training is aimed at a methodical procedure.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

General training aims

The following general training aims can be derived from the main

training aims:

The user designs a production process in the form of a distributed

process and creates the appropriate system.

The user understands "intelligent units" as re-usable technological

modules, whereby certain specific control functions are realised.

The user selects a transport system for a system and integrates this

into the system.

The user familiarises himself/herself with preassembled MPS

standard or MPS 500-FMS systems and understands their design

and mode of operation.

The user familiarises himself/herself with component based

automation (object-oriented procedure during the design and

construction of a system) in practice and uses this.

The user specifies the communication interface between the

different "intelligent units" of a distributed system.

The user designs the communication of a distributed system.

The user designs, modifies and tests PLC programs for individual

"intelligent units".

The user practises structured and modular PLC programming.

The user transmits communication information to the PLC program

in the form of parameters via an interface.

The user incorporates, tests and observes communication

information in the PLC programs of the "intelligent units".

The user locates and eliminates faults in the individual "intelligent

units".

The user carries out systematic fault finding in complex systems.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

Significance of training

contents in industrial

practice

Industrial development over the last few years has been governed by an

ever increasing degree of automation, more and more complex work

processes and faster operational sequences. The keywords here are

optimal utilisation of high investment, flexible and cost effective

production. These include:

High machine efficiency,

Reduction in downtimes,

Modularisation of systems and distributed intelligence,

Optimisation of systems,

Continual improvement processes.

As a result of the above, completely new requirements need to be met

to some extent by all those in direct contact with a system. Operators

and fitters assume small maintenance tasks and eventual repairs.

Maintenance technicians must be able to understand electrical and

electronic control technology up to a certain level to be in a position to

reach conclusions regarding mechanics, pneumatics and hydraulics.

Conversely, electrical engineers require knowledge regarding

pneumatic and hydraulic actuators. These changing requirements in

turn also lead to new forms of collaboration.

By classifying these necessary requirements, the following areas are

created

Technology know-how

System know-how and understanding

Sociocultural skills

CIROS ® Advanced Mechatronics enables you to develop know-how and

learn skills in the areas of technology know-how and system know-how

and understanding. Apart from technical knowledge, these skills also

include handling and methodological competence.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

5.2

Target group

5.3

Prior knowledge

The target group for CIROS ® Advanced Mechatronics includes all those

whose vocational line of activity involves networking, PLC programming

and the maintenance and servicing of networked systems or who

require basic knowledge of these subjects.

These include:

Vocational training

‟ Mechatronic engineers

‟ Electronics engineers, for example specialising in automation

technology

‟ Plant electronics engineers

‟ Industrial mechanics

Specialist qualification in the metal and electrical engineering field

Training at technical colleges and universities

The following prior knowledge is required for training and working with

CIROS ® Advanced Mechatronics:

Basic knowledge of control technology: Structure of an automated

system

Basic knowledge of PLC technology: Design and mode of operation

of a PLC

Basic knowledge of PLC programming and handling of a PLC

programming tool such as the programming system SIMATIC STEP 7

Basic knowledge of pneumatic control technology: Drives, control

elements

Basic knowledge of sensor technology: Limit switches, contactlessly

operating proximity sensors

Basic knowledge of design, wiring and tubing up of

electropneumatic systems.

Basic knowledge of electrotechnology: Electrical variables, the

correlation and calculation thereof, DC and AC current, electrical

measuring techniques

Basic knowledge of how to read and interpret circuit diagrams

Skills in dealing with and operating Windows programs

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

5.4

Example: Allocation of

training aims to syllabi

Below is a table of training aims on the subjects of system know-how,

PLC programming, communication and systematic fault finding. The

training aims are taken from the vocational training syllabus for

mechatronics engineers, status 1999. The contents are correspondingly

adapted and weighted, for example in the syllabi for electrical and

electronics engineers, status 2003.

The skilled trades of mechatronics or electronics engineers are two

examples of how, in Germany, skilled trades are currently updated and

adapted to the concept of new training areas.

The tables only lists those training aims which form part of CIROS ®

Advanced Mechatronics training.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

Training content: Analysis of mode of operation and structure of a system

Vocation Training area Training aim

Mechatronics

engineer

Training area 1:

Analysing of functional

correlations in

mechatronic systems

Training area 4:

Examining energy and

information flow in

electrical, pneumatic

and hydraulic modules

Training area 7:

Realising mechatronic

subsystems

Reading and using technical documentation.

Mastering the procedure for analysing and documenting

functional correlations.

Designing and interpreting block diagrams.

Reading signal flow, material flow and energy flow with

the help of technical documentation.

Reading basic circuits of control technology: Actuation

(pneumatic and hydraulic) of a single-acting and doubleacting

cylinder, basic logic operations, protective circuits,

digital circuits.

Reading and using circuit diagrams.

Familiarisation with supply units in electrics, pneumatics

and hydraulics.

Understanding and describing the control functions of

simple control systems.

Configuring a control system (block diagram).

Understanding signals and measured values in control

systems.

Understanding and describing the structure of

mechatronic subsystems.

Understanding and evaluating the mode of operation,

signal behaviour and use of components (sensors and

actuators).

Understanding basic circuits and the mode of operation

of drives.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

Training content: Analysis of mode of operation and structure of a system

Vocation Training area Training aim

Training area 8:

Design and

construction of a

mechatronic system

Training area 9:

To examine the

information flow in

complex mechatronic

systems

Training area 11:

Commissioning, fault

finding and repairs

Training area 13:

Handover of

mechatronic systems

to customers

Describing the structure and signal characteristics of a

mechatronic system.

Analysing the effect of changing operating conditions on

the process sequence.

Describing the information structure (signal structure,

signal generation, signal transport) of a system.

Setting up the connection between electrical,

mechanical, pneumatic and hydraulic components.

Analysing signals (binary, analogue, digital) and

establishing possible error sources.

Using computer-aided diagnostic methods such as

testing and diagnostic functions of the programming

system or bus system.

Analysing mechatronic systems on the basis of technical

documentation and separating the construction into

function blocks.

Describing a mechatronic system.

Drawing up operating instructions and documentation.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

Training contents: PLC programming and testing of the program

Profession Training area Training aim

Mechatronics

engineer

Training area 7:

Realising mechatronic

subsystems

Training area 8:

Design and

construction of

mechatronic systems

Training area 9:

Examining the

information flow in

complex mechatronic

systems

Training area 11:

Commissioning, fault

finding and repairs

Understanding the design and mode of operation of a

PLC.

Designing and documenting control systems for simple

applications. Programming simple control processes

using a PLC: Logic operations, memory functions, timers,

counters.

Realising the programming in one of the PLC

programming languages: Ladder diagram or statement

list to DIN EN 61131-3.

Documenting control systems in function diagrams and

function chart to DIN EN 60848.

Programming of mechatronic systems in one of the

programming languages: Ladder diagram, function chart,

statement list, sequence language.

Programming operating mode sections.

Programming a sequence control.

Using computer-aided diagnostic methods such as

testing diagnostic functions of the programming system.

Eliminating errors in the PLC program.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

Training contents: Communication within a system

Profession Training area Training aims

Mechatronics

engineer

Training area 9:

Examining the

information flow in

complex mechatronic

systems

Describing the information structure of a system with the

help of circuit diagrams and technical documentation.

Analysing signals and establishing possible error

sources.

Measuring and detecting signal faults in bus systems.

Understanding and realising the networking of

subsystems.

Understanding hierarchies of networked systems.

Using computer-aided diagnostic methods such as

testing and diagnostic functions of the programming

system.

Incorporating changes into existing documentation.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

Training content: Systematic fault finding in systems

Profession Training area Training aim

Mechatronics

engineer

Training area 4:

Examining the energy

and information flow in

electrical, pneumatic

and hydraulic modules

Training area 7:

Realising mechatronic

subsystems

Training area 8:

Design and

construction of

mechatronic systems

Training area 9:

Examining the

information flow in

complex mechatronic

systems

Training area 11:

Commissioning, fault

finding and repairs

Fault finding on simple modules with the help of

measuring technology.

Testing control systems for simple applications, e.g. by

means of signal analysis.

Identifying faults by means of signal analysis at

interfaces, eliminating error causes.

Computer simulation

Analysing signals (binary, analogue, digital) and

establishing possible error sources.

Using computer-aided diagnostic methods, e.g. testing

and diagnostic functions of the programming system.

Understanding procedures for fault finding in electrical,

pneumatic and hydraulic systems.

Carrying out malfunction analysis. Mastering and using

systematic fault finding.

Knowing typical error causes.

Targeted use of diagnostic systems.

Documentating faults.

Drawing up a maintenance and repairs protocol.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

5.5

The training concept of

CIROS ® Advanced

Mechatronics

CIROS ® Advanced Mechatronics is a motivating, multimedia training aid

on the subject of automated systems.

The systems can be flexibly programmed to different levels of

complexity. This enables you to formulate problem definitions according

to the requirements and prior knowledge of trainees whereby, for

example, the mode of operation of individual components can be

examined. It is however also possible to concentrate on the subject and

training for planning the communication in a distributed system or

programming and testing the operating mode part of a system.

The simulated processes have their own didactic quality:

They are as practice-related and real as possible.

The possibility of experimenting with process models establishes an

affective link to actual systems, i.e. the actual training topic, thereby

testing and consolidating knowledge.

The realistic experience with simulated processes provides a new

quality of knowledge: Theoretical knowledge becomes application

and practice-oriented ability.

CIROS ® Advanced Mechatronics supports self-motivated and enquiring

learning:

The simulated system functions in the same way as an actual

system. For example, this immediately shows trainees whether they

have programmed the system sequence correctly. Similarly the

effect of operational errors is apparent without causing damage to

the system. This enables trainees to reach and evaluate conclusions.

Trainees can obtain technical documentation regarding the system

or system components according to requirement.

Trainees can practise their know-how and skills on a wide variety of

systems.

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What are the benefits of tuition using CIROS ® Advanced Mechatronics?

CIROS ® Advanced Mechatronics is a PC-assisted training aid and

therefore represents a different training method. Lessons can be

made stimulating and motivating.

Know-how and skills acquired on actual systems can be improved

and consolidated using practice-related process models.

Simulated processes can be used to illustrate and test situations

which would be dangerous on an actual system.

Efficient, practice-related and task oriented training is possible even

without an actual system.

A system, available only once in reality, is available in multiple

forms. This increases the availability of the system for tuition.

The real and virtual world of automation technology can be

combined in any way and adapted to the training process required.

All systems simulated in CIROS ® Advanced Mechatronics are also

available in the form of actual systems. This provides ideal additions

and combinations for tuition.

Activities and skills which can only be acquired on actual systems

should not be replaced but merely supplemented, prepared or dealt

with more extensively.

Simulation is a modern tool used in dealing with automated

systems.

Example 1: To ensure that PLC programs and the design of a system

are completed at the same time, appropriate simulation of system

components or of the complete system is used to test the PLC

program.

Example 2: Since production systems should have as few

downtimes as possible, operators and maintenance staff are often

familiarised with and trained on simulated systems.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

5.6

Training scenarios for

CIROS ® Advanced

Mechatronics

CIROS ® Advanced Mechatronics can be used in many different ways for

vocational and further training. Here are a few examples:

CIROS ® Advanced Mechatronics in the form of an introduction for

the purpose of motivation, preparation and as a knowledge

database for actual MPS systems:

The user has an actual MPS system which he/she wants to

understand and operate.

With CIROS ® Advanced Mechatronics users have the possibility of

creating their actual MPS system in the form of a virtual system.

With the help of this virtual system, users can familiarise themselves

with the automation components and stations of their system.

Information is available on the online Help and via an online

Assistant. Since the control and communication of the system can

be automatically generated, the user does not require any

knowledge of PLC programming and networking of systems for this

phase. System production can be immediately simulated and the

behaviour of the system observed. In line with the user’s problem

definition, one can acquire comprehensive basic knowledge

regarding electrical and pneumatic processes and the components

involved or practise and improve the programming of distributed

systems.

CIROS ® Advanced Mechatronics in the form of an introduction for

the purpose of motivation and preparation on the subject of

distributed automation systems:

CIROS ® Advanced Mechatronics can be used independently of

actual systems. On the basis of a library with automation stations,

the user plans and designs distributed systems of varying

complexity. Typical automation stations include warehouse

administration, robots, processing machines and transport systems.

Information regarding the components and stations is available to

the user on the online Help and via an online Assistant. Since the

control and communication of the system can be automatically

generated, the user does not require any knowledge of PLC

programming and networking of systems. The sequence of the

system can be simulated immediately and the behaviour of the

system observed.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

In line with the user’s problem definition, one can acquire

comprehensive basic knowledge regarding electrical and pneumatic

processes and the components involved, gain an understanding of

distributed processes and practise and improve the programming of

a distributed system.CIROS ® Advanced Mechatronics as a tool for

practising PLC programming in applications of varying complexity:

CIROS ® Advanced Mechatronics can be used independently of

actual systems. On the basis of two libraries with automation

stations, the user plans and creates simple or complex virtual

systems. If the user has prior knowledge in PLC programming,

he/she can change or completely recreate the PLC programs of the

individual stations. As soon as the desired PLC program is available,

the user can simulate the running of the system. Via the simulation,

the user immediately receives feedback as to whether the sequence

of the corresponding station has been correctly programmed. A

major advantage is that users can use the PLC and programming

system of their choice, whereby they have access to the testing and

diagnostic functions of the programming system. These permit quick

and effective fault finding and elimination in the generated PLC

program.

In the case of less practised PLC programmers, systems consisting

of one station can also be created. In this way all the training

contents for which only a single station is required can be taught in

CIROS ® Advanced Mechatronics.

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5. These training contents can be taught using CIROS ® Advanced Mechatronics

CIROS ® Advanced Mechatronics as a tool for practising systematic

fault finding on systems of varying complexity:

With CIROS ® Advanced Mechatronics you can create systems of

varying complexity into which malfunctions can be incorporated. The

task of the trainee is to detect and eliminate the malfunctions during

the operation of a system.

CIROS ® Advanced Mechatronics supports you extensively during the

identification and evaluation of the ACTUAL status of the system:

LEDs on the sensors and valves indicate the electrical status of the

process components. If compressed air is applied to a cylinder

connection, the connection is highlighted in blue. The statuses of

PLC inputs/outputs are shown in a separate window. By using a

nominal/actual comparison you can isolate the location of the fault

and a further systematic procedure enables you to find and

eliminate the fault.

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6. This is how you create and operate a distributed

system in CIROS ® Advanced Mechatronics

6.1

Training aims

CIROS ® Advanced Mechatronics supports you in a number of different

ways with the creation, familiarisation and analysing of distributed

systems.

The systematic procedure you use and the knowledge you acquire can

be used in any way you choose and of course also on actual systems.

A system is modelled from prepared stations. Whilst the system is

simulated, you can operate, observe and analyse it. The system

behaviour corresponds exactly to how this is defined in the PLC

programs provided for the individual stations. During simulation, the

PLC programs supplied are executed by the internal controller of each of

the stations. The PLC programs offer a possible sequence and possible

operation of the individual stations of the system. The stations can of

course also be controlled via other PLC programs created by the user.

The following training aims can be taught with the help of CIROS ®

Advanced Mechatronics:

Familiarisation with and understanding of the design and mode of

operation of a distributed system.

Familiarisation with typical components for the realisation of

automated systems: Sensors and limit switches, pneumatic valves,

pneumatic linear and rotary drives, electrical DC motors,

programmable logic controllers.

Modelling distributed systems from intelligent stations.

Operating and observing distributed systems.

Networking the stations of a distributed system.

Familiarisation with different production processes.

Evaluating technical documentation.

Researching information.

Recognising the advantage of a simulated system for industrial

operation.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

6.2

Support via CIROS ®

Advanced Mechatronics

6.3

Example: Configuration of

a distributed system from

MPS ® Standard stations

and simulating production

Exercise

CIROS ® Advanced Mechatronics supports you with the following during

the creation and familiarisation with distributed systems:

Library with prepared stations or station combinations. The stations

are intelligent, autonomous system sections which perform specific

machine functions.

Editor for the modelling of systems.

Simulation of the modelled system in 3D representation and the

execution of the sample PLC in the internal controllers of the

individual stations.

Windows for PLC inputs/outputs:

Status display of the PLC inputs/outputs of a station.

Manual Operation window:

Status display of all process sequences and statuses.

Manual Operation window:

Manual triggering of process sequences.

CIROS ® Advanced Mechatronics Assistant: Makes information

available online such as the description and circuit diagrams of

stations.

Configure a system for the production of measuring instruments. The

workpiece housings for measuring instruments are to be supplied via

the handling station. After the assembly process, the produced

measuring instruments are to be sorted.

Answer the following questions:

Which stations do you require for the system?

In which sequence must be stations be arranged?

How is the initial position of the system defined?

Which workpieces are required for the production process?

How does the station react if a slide is filled with workpieces on the

sorting station.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

Implementation

1. Start CIROS ® Advanced Mechatronics.

2. Activate the MPS ® System command under New in the File menu.

The Create MPS ® System window is now displayed.

3. Select a subdirectory for the new station as storage location. Enter

the file name. Select CIROS ® Workcells (*.mod).under file type.

Then click onto the Save button.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

4. The model of an empty system is now displayed. When a new

system is created, a number of settings are carried out automatically

in CIROS ® Advanced Mechatronics:

‟ The program changes into Edit Mode,

‟ A table with possible workpieces is made available,

‟ The view selected is Top View,

‟ The Model Libraries window is opened.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

5. Create the required system using the station models from the MPS ®

Stations Library. A brief description and preview of the individual

models is displayed if you highlight the library entry for the model

and then click onto the Details button.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

6. You will find detailed information regarding the stations in the

library on the online Help in the chapter CIROS ® Advanced

Mechatronics. Start Help by activating the Examples and Models of

CIROS ® Advanced Mechatronics command in the Help menu. For

example a function description and technical documentation for the

station are offered.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

Result

7. Now check which station you need for the required system and how

the system is to be configured.

Your investigation shows that you will need the Pick & Place and Fluidic

Muscle press stations for the assembly process. In addition you will

also need the handling station – adjusted for successor station and the

sorting station. The stations are placed directly next to one another and

are coupled via optical sensors.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

8. Now create the system. First insert the handling station. To entries

are available to you for this station in the library. Since an additional

station will be added to the handling station, you require the

handling station – adjusted for successor station. Highlight the

entry Handling – Adjusted for Successor via a mouse click. Then

click the Add button.

The system now consists of the handling station– adjusted for

successor station model. This station is shown in green since it is

still highlighted.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

9. Simply click outside of the station if you want to cancel the

highlighting of the station.

A coupling point is shown on both sides of the station. This indicates

that the station can be connected to an additional station at this

point.

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10. Now enter the Pick & Place station as an additional station.

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11. All stations are inserted at the same position of the work space.

Move the newly added Pick & Place station by clicking onto the

highlighted station and moving the mouse pointer to the required

position whilst holding down the left mouse button.

12. The two models are positioned next to one another but are not yet

connected. To ensure that working and transfer positions coincide

during the production run of the system, both station models must

be correspondingly aligned and connected.

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13. Now align the Pick & Place station model with the handling station

– adJusted for successor station.

To do so, click onto the bottom grey shaded coupling point of the

Pick & Place station. Hold down the left mouse button and drag the

coupling point onto the coupling point of the handling station -

adjusted for successor station.

The Pick & Place station is now connected to the handling station –

adjusted for successor station.

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14. Now enter the Fluidic Muscle press station as the next station. This

station is also shown at the predefined point in the activity window.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

15. Click onto the newly added, still highlighted station and move this

up next to the Pick & Place station.

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16. Connect the Fluidic Muscle press station model to the upper, free

coupling point of the Pick & Place station model.

To do so click onto the lower, grey shaded coupling point of the

Fluidic Muscle press station. Hold down the left mouse button and

drag the coupling point to the free coupling point of the Pick &

Place station.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

17. Add the sorting station as the last station. Connect the sorting

station to the Fluidic Muscle press station.

18. The system is now configured. Change into the view mode to obtain

a realistic 3D representation of the system.

Deactivate the Edit Mode command in the Modeling menu by

clicking onto the Edit Mode command. The check mark next to the

Edit Mode entry is removed.

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19. A 3D representation of your system is displayed. The representation

also shows a top view.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

20. To obtain a perspective view of the 3D model, select the Standard

Views/Default Settings command in the View menu. Move, rotate

and zoom into an appropriate view of your system by using the

commands under View.

21. Prior to simulating production of the system, the system should be

in the initial position. This is achieved by executing the Reset

Workcell command in the Simulation menu. By executing this

command, all the workpieces on the system are also removed.

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22. Now activate the Start command in the Simulation menu.

Simulation of the system is now active. You can identify the

simulation mode via the Running entry.

23. Each station has an internal PLC. The supplied sample PLC program

is executed with the start of virtual system simulation.

The stations can now be operated using the keys and switches of

the corresponding control console. The sequence of operation is

defined in the PLC program.

24. Once simulation is started, the illuminated reset button requests the

reset function for all stations. The system is moved into the initial

position via the reset function.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

25. To obtain information in the technical documentation regarding the

initial position of the system, open the CIROS ® Advanced

Mechatronics Assistant. Activate the Examples and Models of

CIROS ® Advanced Mechatronics command in the Help menu. Click

onto the CIROS ® Advanced Mechatronics entry. In the chapter

MPS ® Standard you will find the required information regarding the

individual stations in the technical documentation.

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Result

Initial position for the handling station: Linear axis in "predecessor

station" position (1B2=1) and lifting cylinder retracted (gripper up)

and gripper open.

Initial position for the Pick & Place station: Feed separator advanced

and conveyor motor off. Mini slide up and mini slide retracted and

vacuum off.

Initial position for the Fluidic Muscle Press station: Linear drive

retracted and rotary drive in pick-up position ("predecessor station

position") and pressb up.

Initial position for the sorting station: Locking device advanced and

sorting gate 1 retracted and sorting gate 2 retracted and conveyor

motor off.

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26. Execute the reset function for each station by clicking the reset

button. We recommend that you carry out the reset of the individual

stations against the material flow.

In the case of this system, this means: Execute the reset mode of the

sorting station, then the reset mode of the Fluidic Muscle press

station, followed by that of the Pick & Place station and finally the

reset mode of the handling station.

27. The illuminated start button of a station indicates that the

respective station is now in the initial position.

28. Check whether the start conditions for the individual stations are

fulfilled. You will find the information for this in the technical

documentation for the individual station in CIROS ® Advanced

Mechatronics Assistant.

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Result

Start conditions of the individual stations:

Handling station: Workpiece in the workpiece holde

Pick & Place station: No workpiece at conveyor start and slide with

workpiece inserts filled

Fluidic Muscle press: No workpiece in gripper

Sorting station: No workpiece at conveyor start

29. Make sure that the workpieces necessary for the production process

of the system are available:

‟ One workpiece housing at the transfer position of the handling

station,

‟ At least one workpiece insert on the slide of the Pick & Place

station.

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6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics

30. To supply a workpiece to the handling station, click onto the desired

workpiece on the workpiece table. For example select the red

measuring instrument housing. Then click onto the symbolic

workpiece of the handling station.

A red measuring instrument housing is made available on the

workpiece holder of the handling station.

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31. Now fill the slide of the Pick & Place station with measuring

instruments by clicking onto the symbolic measuring instrument of

the Pick & Place station.

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32. Start the sequence of each station by clicking onto the start button.

The automatic mode of the station is started. We recommend that

you start the stations in the order in which they are arranged in the

material flow.

33. With the key actuator you can select either continuous cycle (switch

position vertical) or individual cycle (switch position horizontal) for a

station sequence.

34. The sequence of a station can be interrupted at any time by pressing

the stop button. If you want to restart the station, you need to

execute the reset function first.

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35. If a slide of the sorting station is filled with workpieces, the station

does not accept any additional workpieces. Warning light Q1 is

illuminated.

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36. Remove the workpieces by executing the appropriate command in

the manual operation window.

Click onto the Manual Operation command in the Modeling menu.

Double click onto the + symbol in front of sorting station on the left

side of the window to display all the activities of the station.

Double click the Empty Slides entry.

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37. Acknowledge the removal of the workpieces by pressing the start

button. The production process of the system is then continued.

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7. This is how you analyse information flow in a

distributed system

Note

The exercise is intended as an introduction to the subject of networking

stations. The networking is dealt with in the form of an example using

the distributing, testing and sorting stations.

The PLC programs are created such that they can be used for stand

alone operation of the stations. At the same time, these PLC programs

also support working with the stations in a network whereby minimal

information about process inputs/outputs is exchanged between the

stations.

In the standard version, MPS ® Standard stations are coupled with

optical sensors. This type of coupling is known as StationLink. Throughbeam

sensor emitters and receivers are used as StationLink sensors.

The StationLink emitter is mounted on the material input side of the

station and the StationLink receiver on the material output side. By

switching on and off the StationLink emitter, the predecessor station

signals whether it is ready to accept a workpiece or occupied.

In the case of the distributing station only the StationLink receiver is

mounted.

In the case of the sorting station, only the StationLink emitter is

mounted.

The user analyses how simple communication functions and how it is

realised.

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7. This is how you analyse information flow in a distributed system

7.1

Training aims

7.2

Methods

The following training aims can be taught with the use of CIROS ®

Advanced Mechatronics:

Understanding simple communication between the stations of a

distributed system.

Realising simple communication between stations via process

inputs/outputs.

Incorporating simple communication into the PLC program of a

station.

Understanding structured, programmed PLC programs.

Evaluating technical documentation.

Researching information.

Recognising the advantage of a simulated system for industrial

operation.

Proceed step by step to analyse the networking and information flow in

a system. Each step deals with an important aspect of communication.

The main aspects of communication are listed below.

Questions regarding the individual aspects offer suggestions and

guidance as to what you should examine and consider.

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7. This is how you analyse information flow in a distributed system

Main aspects Questions

Function of communication What is the function of communication?

‟ To ensure the safe transfer of workpieces

‟ To transmit information regarding the workpieces

‟ To pass on job orders to the stations

Information that is exchanged How does communication function?

‟ What is the meaning of the signal which the information transmits?

‟ Via which absolute address is the signal evaluated?

‟ What data type is the signal?

Realisation of communication How is communication realised?

‟ Via the coupling of PLC inputs/outputs

‟ Via the use of a fieldbus

Components for communication What components are used to establish communication:

‟ Direct connection of PLC inputs/outputs

‟ Optical sensors for signal transmission

‟ Communication modules in field devices

Structure of communication How are the components assembled?

What needs to be considered when connecting stations?

Connection of components What does the connection of components look like?

Communication in PLC

programs

Main aspects of communication within a system

How is communication incorporated into PLC programs?

Is communication information transmitted to the relevant program

sections via global variables or via parameters?

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7. This is how you analyse information flow in a distributed system

7.3

Support via CIROS ®

Advanced Mechatronics

7.4

Example: Analysing

information flow in a

distributed MPS ®

Standard system

Exercise

CIROS ® Advanced Mechatronics supports you as follows during the

analysis of communication in distributed systems:

Simulation of the modelled system in 3D representation and

execution of sample PLC programs in the internal controllers of

individual stations.

Windows for PLC inputs/outputs:

Status display of the inputs/outputs of a station.

Manual operation window:

Status display of all process activities and process statuses.

Manual operation window:

Status display of communications links.

CIROS ® Advanced Mechatronics Assistant:

Online information such as descriptions, circuit diagrams and PLC

programs of stations.

Analyse the communication in an MPS ® Standard system. Select the

combination of the distributing, testing and sorting stations as the

system. Consider the following questions when analysing the

communication:

What is the function of communication?

What information is exchanged?

How is communication realised?

Via what components is communication established?

How are the components assembled, what is to be considered when

coupling the stations?

What does the connection of components look like?

How is communication incorporated into the PLC programs?

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7. This is how you analyse information flow in a distributed system

Implementation

1. Start CIROS ® Advanced Mechatronics.

2. Create an MPS ® Standard system consisting of the distributing,

testing and sorting stations.

As the distributing station is coupled with the testing station, select

the station with the library entry Distributing – Adjusted for Testing

in the model library.

3. Deactivate the Edit Mode as soon as the station is created. Change

to View mode by clicking the Edit Mode command in the Modeling

menu. The check mark next to the Edit Mode entry is removed.

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7. This is how you analyse information flow in a distributed system

4. Close the model library and select a perspective view of the system

by activating the Standard Views/Default Setting command in the

View menu. Using the command in the View menu, create the

desired representation of the system.

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7. This is how you analyse information flow in a distributed system

5. Refer to the technical documentation on the online Help to find out

what functions communication realises in MPS ® Standard systems.

To do so, activate the Examples and Models of CIROS ® Advanced

Mechatronics command in the Help menu. Click onto the CIROS ®

Advanced Mechatronics entry. In the chapter Getting Started you

will find a section about communication between stations.

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7. This is how you analyse information flow in a distributed system

Result

The function of communication is to enable the reliable transfer of a

workpiece from the distributing station to the testing station.

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7. This is how you analyse information flow in a distributed system

Result

6. Use the technical documentation for the two stations for information

as to how communication functions:

‟ Which information is transmitted?

‟ Which data type carries the signal which transmits information?

Distributing station Testing station

Material flow

“Station occupied” bit

“Station occupied” = 1 means:

Testing station has no

requirement. Distributing station

must not output.

Station occupied = 0 means:

Testing station has requirement

and requests a workpiece.

Distributing station is permitted

to output.

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7. This is how you analyse information flow in a distributed system

7. Refer to the technical documentation for the two stations to find out

what system resources the PLC uses to realise communication.

To do so activate the Examples and Models of CIROS ® Advanced

Mechatronics command in the Help menu. Click onto the CIROS ®

Advanced Mechatronics entry. In the chapter MPS ® Standard you

will find the appropriate stations and relevant technical

documentation.

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7. This is how you analyse information flow in a distributed system

Result

Distributing station Testing station

The signal is inverted

at the receiving end.

Information is exchanged

via

Input of the PLC

Output of the PLC

Distributing station

0-Signal

1-Signal

“Station occupied” bit

1-Signal

0-Signal

“Station occupied” bit

I 0.7 Q 0.7

Information is exchanged

via

Input of the PLC

Output of the PLC

Testing station

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7. This is how you analyse information flow in a distributed system

Result

Result

Result

8. Refer to the technical documentation for the two stations to find out

which components are used to transmit the information "Station

occupied".

Components of the distributing station

Optical sensor: Through-beam sensor, receiver

Components of the testing station

Optical sensor: Through-beam sensor, emitter

9. Find out what is to be considered when coupling the stations.

To ensure that the communication signal is transmitted error-free via

the optical StationLink sensors, the optical sensors of the neighbouring

stations must be positioned flush and directly opposite one another.

This can be achieved by connecting the stations via the coupling points.

10. Refer to the technical documentation to find out where in the

diagram the components for the realisation of communication are

taken into account.

Sheet Column Designation

Circuit diagram of distributing station

4 9 Sensor IP_FI, through-beam sensor,

receiver

Circuit diagram of testing station

5 9 Sensor IP_N_FO, through-beam sensor,

emitter

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7. This is how you analyse information flow in a distributed system

11. Now observe the production process of the system.

Start simulation by activating Start in the Simulation menu.

12. The illuminated reset button requests the reset function on all

stations.

13. Reset the individual stations agains the material flow.

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14. Make sure that the required workpieces are available for the

production process of the system.

Fill the magazine of the distributing station with, for example, red

basic cylinder bodies. To do so, click onto the required workpiece on

the workpiece table. Then click onto the symbolic workpiece on the

distributing station. Each mouse click on the symbolic workpiece

causes the magazine to be filled with a workpiece.

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7. This is how you analyse information flow in a distributed system

15. Start the sequence of each station by clicking onto the start button.

We recommend that you start the stations in the order in which they

are arranged in the material flow.

16. Once all the workpieces have been tested and sorted, stop the

simulation by clicking onto the Running field.

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17. Next observe the status of the communication variables during the

production process of the system.

To do so, open the Manual Operation window in the Modeling

menu.

18. Hide the section of the window with the display of I/O connections

as you do not need this information. Activate the context-sensitive

menu via the right mouse button and deactivate the Show I/O

Connections command.

19. If you merely want to observe the changes in communication

signals, then set the stops at the appropriate signals. Simulation

stops as soon as the relevant signal changes its value and you can

observe the sequence at your leisure.

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7. This is how you analyse information flow in a distributed system

20. Double click the + symbol in front of the distributing station in the

lefthand section of the window. All the process sequences of the

distributing station are now displayed.

The process statuses of the testing station can be displayed in the

righthand section of the window.

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7. This is how you analyse information flow in a distributed system

21. Highlight the variable IP_N_FO station occupied of the testing

station under Process Status and set a stop. Open the contextsensitive

menu of the righthand mouse button and select the Stop

at Value Change command. The variable IP_N_FO is marked with a

STOP symbol.

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7. This is how you analyse information flow in a distributed system

22. Open the PLC inputs window to also observe the communication

signal of the distributing station.

Activate the Show Inputs command under Inputs/Outputs in the

View menu.

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23. Select the controller whose PLC inputs/outputs you want to

observe. Click onto the Controller Selection command in the

Programming menu. In the Current column, select the controller for

the distributing station as controller.

24. Start simulation of the system by clicking onto the Stopped button

in the status bar.

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7. This is how you analyse information flow in a distributed system

25. The indicator light Q1 on the control console of the distributing

station indicates the workpieces are missing.

26. Fill the magazine of the distributing station with correct workpieces

again.

27. Acknowledge the activity and click onto the illuminated start button.

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28. The distributing station ejects a new workpiece from the magazine

and passes it on to the testing station. Simulation then stops

because the Variable IP_N_FO of the testing station changes its

value. The testing station signals "station occupied=1", because

the station has no requirement. A workpiece is already present in

the holder.

29. Restart simulation to continue the execution of the production

process by clicking onto the Stopped button in the status bar.

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7. This is how you analyse information flow in a distributed system

30. In the next simulation cycle, the signal STATION_IP_FI successor

station free of the distributing station is updated in the Inputs

window. Its value is changed to 0. The distributing station must

therefore not pass on a further workpiece to the testing station.

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31. The testing station now tests the current workpiece. As soon as the

station has completed the process of testing and passed on the

workpiece to the sorting station, it can accept a new workpiece. The

testing station changes the value of the variable IP_N_FO. It now

sends the signal "Station occupied=0". The signal change causes

simulation to stop.

32. Restart simulation.

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7. This is how you analyse information flow in a distributed system

33. In the next simulation cycle, the signal "station occupied" is read

inverted as "successor station free" by the distributing station. It is

therefore permissible for the distributing station to start output.

34. With the simulation of the system you have now analysed how

communication between the distributing and testing stations

functions.

In the GRAFCETs for the stations you can reproduce in detail how

and at which points in the PLC program communication is taken into

consideration. You will find the GRAFCETs in the technical

documentation for the stations.

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7. This is how you analyse information flow in a distributed system

35. You can analyse the communication between the testing and sorting

stations in the same way by using simulation and the technical

documentation.

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