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 

© Festo Didactic GmbH & Co. KG „ 572761 3

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 

4 

© Festo Didactic GmbH & Co. KG „ 572761

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. 



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. 

6 



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. 


2. This is how you install CIROS ® Advanced 


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. 

8 


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. 


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 ® 


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: 

10 


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 ® 


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. 



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, 

12 

© Festo Didactic GmbH & Co. KG „ 572761 

... 

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.


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. 



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. 

14 



3.2 

A distributed system in 

CIROS ® Advanced 


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. 



Example of an MPS ® Standard system 

Example of an MPS ® 500-FMS system 

16 



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. 



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. 

18 



3.4 

The preassembled station 

models in CIROS ® 


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. 





This model is a simulation of the MPS ® handling station 


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. 

20 




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. 




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. 

22 




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. 




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. 

24 




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. 




Distributing station 

This model is a simulation of the MPS ® distributing station 


separated and passed on to the neighbouring station. 

26 



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. 



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 

28 




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 




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. 

30 



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. 



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. 

32 



3.9 

Directory and file 

structure of CIROS ® 


Directory structure 

following the installation 

of CIROS ® Advanced 


Here you obtain information about the directory and file structure of 


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. 



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 


MPS 500-FMS automated 

warehouse station 

MPS 501-FMS system 

Workcell for 

MPS 501-MPS system 




MPS Standard system 

with separating station 

MPS Standard system with 

distributing and testing stations 

(multi bit communication) 


distributing and testing stations 

(one bit communication) 


distributing, testing and 

sorting stations 

(one bit communication) 

PLC and robot programs for 

all MPS stations 

34 



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. 



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. 

36 



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. 


4. Main control functions of CIROS ® Advanced 


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, 

38 


4. Main control functions of CIROS ® Advanced Mechatronics 

Note 


Sorting 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. 



This is how you 

combine your 

MPS ® Standard 

stations 

Distributing ‟ Standard 

Distributing ‟ adjusted 

for testing 

Testing 

Processing 

Handling ‟ adjusted for 

successor station 


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 

40 


Processing 

Handling – adjusted 

for successor station 

Handling –adjusted 

for termination 

Buffer 

Pick & Place


This is how you 

combine your 

MPS ® Standard 

stations 

Distributing ‟ Standard 

Distributing ‟ adjusted 

for testing 

Testing 

Processing 


successor station 


termination 

Buffer 

Pick & Place 


Separating 

Storing ‟ Stock up 

Storing ‟ Take out 

Robot 


Sorting 


Permisible station combinations for MPS ® Standard systems 

Separating 

Storing – Stock up 

© Festo Didactic GmbH & Co. KG „ 572761 41 

Storing – Take out 

Robot 


Sorting


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. 

42 



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. 



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. 

44 



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. 



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. 

46 



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. 



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

using the commands in the View menu. 

48 



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. 



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. 

50 



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. 



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

at the predefined position in the activity window. 

52 



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

next to the testing station. 



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. 

54 



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. 



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. 

56 



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. 



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. 

58 



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 


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,



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. 

60 



Note 

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


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. 



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. 

62 



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 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. 



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. 

64 



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. 



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. 

66 



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

model by double clicking onto Product Input. 



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. 

68 



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. 



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. 

70 



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. 



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

shown at the predefined position in the activity window. 

72 



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

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




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. 

74 



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. 




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. 

76 



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. 



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. 

78 



This is how you modify an already created system 


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. 



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. 

80 



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. 



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. 

82 



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. 



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. 

84 



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

it up. 



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

entry Pick & Place Station. 

86 



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. 



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. 

88 



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

Connect this station to the Pick & Place station. 



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. 

90 



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

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




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. 

92 



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. 



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. 

94 



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_Q0 COMM_I4 




 

 

 

 

 

 

 

 

 

 

 

 

IP_N_FO IP_FI 

 

I4 Q6 

I5 Q7 

Q4 I6 

Q5 I7 









The prepared default communication links for an MPS ® Standard system 

Note 


 

 

 

 

 

 

 

 

 

 

 

 

IP_N_FO 

 

I4 Q6 

I5 Q7 

Q4 I6 

Q5 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.



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 



96 




Symbolic 

address 

Absolute 

address 

Symbolic 

address 

Absolute 

address 

Symbolic 

address 






Absolute 

address 

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








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. 



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 


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. 

98 



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 









 

IP_N_FO IP_FI 

 

I4 

 

 

 

 

 

 

 

 

I5 

Q4 

Q5 

station 


I6 

I7 

Q6 

Q7 









 

 

 

 

 

 

 

 

 

 

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.


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 

100 



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 




Absolute 

address 

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




COMM_Q0 Q2.0 COMM_Q0 Q2.0 








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



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. 

102 



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. 



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. 

104 



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. 



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. 

106 



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. 



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. 

108 



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. 



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. 

110 



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. 



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. 

112 



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. 



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. 

114 



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. 



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 


116 



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 


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. 



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. 

118 



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. 



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. 

120 



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 


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. 



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. 

122 



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. 



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 

124 



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 


Storage station 



Robot station 








Fluidic Muscle Press station 


Pick & Place station 








Workpiece for MPS ® Standard systems 


Correct intermediate product: 

Housing for measuring 

instrument with applied 

measuring insert in different 

designs 

Black 

Red 

Metal 




126 




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 










Processing station· 





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. 

128 



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. 



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. 

130 



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. 



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. 

132 



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. 



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. 

134 



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. 



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. 

136 



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. 



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. 

138 



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. 



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. 

140 



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


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. 



142 



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. 



Close the Properties for workcell window. 

Close the Model Explorer window. 

The respective sensor lines are now shown in the system. 

144 



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. 



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 

146 


X 

Turn 

Y 

Angle


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. 



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%. 

148 



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. 



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. 

150 



This is how you open the Inputs window 

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

active. 



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. 

152 



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. 



This is how you open the Outputs window 

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

active. 

154 



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. 



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. 

156 



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. 



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. 

158 



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. 



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. 

160 



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. 



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. 

162 



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. 



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

open the window by activating Manual Operation under 

Workspaces in the Windows menu. 

164 



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. 



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. 

166 



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. 



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. 

168 



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. 



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. 

170 



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. 





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 


172 



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. 



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

indicates that a stop is set at this signal. 

174 



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. 



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. 

176 



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. 



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. 



4. If the I/O connections are displayed in the Manual Operation 

window, then hide these. 

178 



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. 



6. All lines with valve coils now show stops. 

180 



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. 



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. 

182 



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. 



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 


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. 

184 



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. 




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. 

186 



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. 



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. 

188 



This is how you load a PLC program to an internal PLC (alternative 

method) 

1. Make sure that the desired MPS system is loaded. 


3. Open the S7 Program Manager by activating the S7 Program 

Manager command in the Programming menu. 



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. 

190 



5. Open the context-sensitive menu via the right mouse button and 

select the Load command. 

6. The Open window is now displayed. 



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. 

192 



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. 



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. 

194 



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. 



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. 

196 



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. 



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. 

198 



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 


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. 



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. 

200 



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. 



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. 

202 



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. 



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. 

204 



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. 



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. 

206 



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. 



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. 

208 



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. 



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. 

210 



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. 



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. 

212 



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. 



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. 

214 



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. 



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) 

216 



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. 



This is how you control a station of the virtual system with 

CoDeSys SP PLCWinNT 

1. Start CoDeSys and open the desired CoDeSys project. 

218 



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. 



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. 

220 



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. 



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. 

222 



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. 



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. 

224 



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. 



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. 

226 



17. Select Dump symbol entries, then click on the configure symbol file 

button. 

This opens the Set object attributes window. 



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. 

228 



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. 



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. 

230 



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. 



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. 

232 



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. 


30. Check whether the system is meant to be in the basic setting. If so, 

activate the Reset Workcell order in the Simulation menu. 



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. 

234 



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. 



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. 

236 



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. 


36. Make sure that the process model simulation is active in CIROS ® 




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. 

238 



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. 



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. 

240 



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. 




EasyPort 

PLC 

Possible configuration with hardware PLC and two PCs 


242 



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. 



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 

244 



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. 



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 


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


PLC board 

Configuration with PLC board 

Process model 

EasyPort 

RING IN OUT MODE RS232 - 24V + 

STATUS SHORT 

XMA2 XMG1 


INPUT 

EasyPort D16 

OUTPUT 

0 7 8 

15 

PORT 1 PORT 2 

1 2 3 

ON


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. 

248 



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. 



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. 


10. Check whether the system is to be in the initial position. If so, 

activate the Reset Workcell command in the Simulation menu. 

250 



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. 



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. 

252 



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. 



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. 

254 



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. 



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. 


18. Make sure that the required PLC program is installed in the PLC. 

19. Start the PLC. 

256 



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. 



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. 

258 



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. 



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. 

260 



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. 



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. 

262 



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. 



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. 

264 



10. Now activate the fault simulation mode by selecting Fault 

Simulation in the Extras menu under Fault Simulation. 



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. 

266 



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. 



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. 

268 



3. The Fault Localisation window is now displayed. 

4. Double click the + symbol of the distributing station to view all 

possible faults. 



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. 

270 



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. 



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. 

272 



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 ® 


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. 


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. 

274 


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. 



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. 

276 



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 



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. 

278 



Training content: Analysis of mode of operation and structure of a system 

Vocation Training area Training aim 


engineer 

Training area 1: 

Analysing of functional 

correlations in 

mechatronic systems 


Examining energy and 

information flow in 

electrical, pneumatic 

and hydraulic modules 


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. 



Training content: Analysis of mode of operation and structure of a system 

Vocation Training area Training aim 


Design and 

construction of a 

mechatronic system 


To examine the 


complex mechatronic 

systems 


Commissioning, fault 

finding and repairs 


Handover of 


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. 

280 



Training contents: PLC programming and testing of the program 

Profession Training area Training aim 


engineer 



subsystems 


Design and 

construction of 



Examining the 



systems 




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. 


testing diagnostic functions of the programming system. 

Eliminating errors in the PLC program. 



Training contents: Communication within a system 

Profession Training area Training aims 


engineer 


Examining the 



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. 


testing and diagnostic functions of the programming 

system. 

Incorporating changes into existing documentation. 

282 



Training content: Systematic fault finding in systems 

Profession Training area Training aim 


engineer 


Examining the energy 

and information flow in 

electrical, pneumatic 

and hydraulic modules 



subsystems 


Design and 

construction of 



Examining the 



systems 




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. 



5.5 

The training concept of 



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. 

284 



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. 



5.6 

Training scenarios for 



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. 

286 



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 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: 


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. 

288 


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. 


6. This is how you create and operate a distributed system in CIROS ® Advanced Mechatronics 

6.2 

Support via CIROS ® 


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. 

290 



Implementation 


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. 



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 Model Libraries window is opened. 

292 



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. 



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. 

294 



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. 



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. 

296 



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. 



10. Now enter the Pick & Place station as an additional station. 

298 



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. 



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 - 


The Pick & Place station is now connected to the handling station – 


300 



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. 



15. Click onto the newly added, still highlighted station and move this 

up next to the Pick & Place station. 

302 



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. 



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. 

304 



19. A 3D representation of your system is displayed. The representation 

also shows a top view. 



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. 

306 



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. 



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. 

308 



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. 



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. 

310 



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. 



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. 

312 



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. 



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. 

314 



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. 



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. 

316 



37. Acknowledge the removal of the workpieces by pressing the start 

button. The production process of the system is then continued. 


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. 

318 


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. 



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? 

320 



7.3 

Support via CIROS ® 


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? 



Implementation 


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. 

322 



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. 



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. 

324 



Result 

The function of communication is to enable the reliable transfer of a 

workpiece from the distributing station to the testing station. 



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. 

326 



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. 



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 


0-Signal 

1-Signal 


1-Signal 

0-Signal 


I 0.7 Q 0.7 

Information is exchanged 

via 

Input of the PLC 

Output of the PLC 


328 



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 



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. 



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. 

332 



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. 



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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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. 



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. 



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. 



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. 



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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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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Manual CIROS® Advaned Mechatronics EN - Festo Didactic

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