682526 EN
06/04
COSIMIR® PLC
Manual
Order No.: 682526
Description: MANUAL
Designation: D:HB-COSI-PLC-EDU-EN
Edition: 06/2004
Authors: Christine Löffler
Graphics: Doris Schwarzenberger
Layout: 09.06.2004, Beatrice Huber
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2004
Internet: www.festo.com/didactic
E-Mail: [email protected]
The copying, distribution and utilization of this document as well as the
communication of its contents to others without express authorization
is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved, in particular the right to carry out patent, utility
model or ornamental design registration.
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 3
1. What will you learn from the manual?___________________ 7
2. This is how you install COSIMIR® PLC _________________ 10
2.1 System requirements ________________________________ 10
2.2 Installation of COSIMIR® PLC
via on-line activation ________________________________ 12
2.3 Network installation of COSIMIR® PLC __________________ 26
2.4 Installation of the communication program EzOPC ________ 28
3. These functions support you in the preparation
of PC workstations for students _______________________ 29
3.1 Description of files for a process model _________________ 29
3.2 Creating a user-specific working environment ____________ 30
3.3 Creating files with fault settings
for a process model _________________________________ 33
4. The COSIMIR® PLC system ___________________________ 37
4.1 Overview of COSIMIR® PLC ___________________________ 37
4.2 The process models of COSIMIR® PLC __________________ 39
4.3 Controlling the process models via internal PLC __________ 44
4.4 Controlling the process models via external PLC __________ 45
4.5 Functions for fault setting
in the process model ________________________________ 47
4.6 Functions for the analysis of process models_____________ 48
Contents
Contents
4 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
5. Important control functions of COSIMIR® PLC ___________ 50
5.1 Loading the process model ___________________________ 50
5.2 Simulating the process model ________________________ 59
5.3 Displaying and operating a process model ______________ 62
5.4 Changing the view of the process model ________________ 65
5.5 The Inputs and Outputs windows ______________________ 69
5.6 The Manual Operation window ________________________ 70
5.7 Controlling a process model via the internal S7 PLC _______ 84
5.8 Controlling a process model via the external
Soft PLC S7-PLCSIM _________________________________ 94
5.9 Controlling a process model via an external PLC _________ 108
5.10 Setting faults in the process model____________________ 121
5.11 Eliminating faults in the process model ________________ 129
5.12 Logging of fault elimination __________________________ 134
6. The following training contents can be taught with
COSIMIR® PLC ____________________________________ 136
6.1 Training contents __________________________________ 136
6.2 Target group ______________________________________ 137
6.3 Previous knowledge ________________________________ 138
6.4 Example: Assigning of training aims to training syllabi ____ 138
6.5 The training concept of COSIMIR® PLC _________________ 143
7. This is how you establish the mode of operation and
structure of a system in COSIMIR® PLC _______________ 145
7.1 Training aims _____________________________________ 145
7.2 Methods _________________________________________ 146
7.3 Support via COSIMIR® PLC __________________________ 150
7.4 Example _________________________________________ 150
7.5 Example _________________________________________ 156
7.6 Example _________________________________________ 161
Contents
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 5
8. This is how you establish the mode of operation of the
components forming part of a system in COSIMIR® PLC __ 166
8.1 Training aims _____________________________________ 166
8.2 Methods _________________________________________ 167
8.3 Support via COSIMIR® PLC __________________________ 167
8.4 Example _________________________________________ 168
9. This is how you use COSIMIR® PLC in PLC programming _ 175
9.1 Training aims _____________________________________ 175
9.2 Methods _________________________________________ 176
9.3 Support via COSIMIR® PLC __________________________ 178
9.4 Example _________________________________________ 178
9.5 Example _________________________________________ 185
10. This is how you carry out systematic fault finding
on a simulated system _____________________________ 193
10.1 Training aims _____________________________________ 193
10.2 Methods _________________________________________ 194
10.3 This is how COSIMIR® PLC supports you________________ 201
10.4 Example _________________________________________ 201
6 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 7
COSIMIR® PLC is a PC-based graphic 3D simulation system consisting of
preassembled process models. These process models represent
automated systems of varying complexity.
COSIMIR® PLC is a tool, which enables you
• to familiarise yourself with the mode of operation and structure of a
system,
• to practise PLC programming and testing of the PLC programs und
• to carry out systematic fault finding on systems.
These process models, also called work cells, are also available in the
form of actual systems.
This manual is intended for
• Instructors
The manual provides ideas and suggestions on how COSIMIR® PLC
can be used for tuition in vocational and further training.
• Teachers
The information and instructions on how to operate COSMIR PLC are
of particular interest to the above.
The manual is subdivided into the following subject areas:
• Chapter 2 contains information and notes regarding the installation
of COSIMIR® PLC .
• Chapter 3 contains information on how to set up COSIMIR® PLC on
students’ PC workstations.
• Chapters 4 and 5 describe the system and the main user functions of
COSIMIR® PLC .
• Chapter 6 deals with didactic aspects and lists the training contents
taught with COSIMIR® PLC . It also describes the training concept
and the resulting possibilites for use in tuition.
1. What will you learn from the manual?
What is COSIMIR® PLC ?
Target group
Composition of the manual
1. What will you learn from the manual?
8 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
• Chapters 7 to 10 describe actual problem definitions regarding the
training contents, the methodical approach to solutions and their
realisation in COSIMIR® PLC . The exercises are for example carried
out on the distribution station.
Certain print formats have been used for text as well as key
combinations and sequences to enable you to find information more
easily.
Print format Meaning
Bold This format is used for command names,
menu names, dialog window names, directory
names and command options.
Key1 + key2 A plus sign (+) between the key names means
that you must press the keys mentioned
simultaneously.
Key1 – key2 A minus sign (–) between the key names
means that you need to press the keys
mentioned in succession.
Additional descriptions and support are available via the on-line Help.
The on-line Help comprises
• COSIMIR® Help with operation and
• COSIMIR® PLC Assistant.
The on-line Help consists of detailed information regarding the
functions and operation of COSIMIR® PLC .
Conventions
Additional support
1. What will you learn from the manual?
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 9
This Help function is also a component part of the software package
COSIMIR® Rob. COSIMIR® Rob has a wider function scope than
COSIMIR® PLC and the combined on-line Help therefore describes more
functions than those required for COSIMIR® PLC .
The menu bar of the on-line Help provides functions that you are
already familiar with from using a standard Internet browser. These
include: Next and back, select start page, print selected topics, show
and hide the navigation bar or Internet connection options.
The additional indexes such as Contents, Index, Search or Favourites,
furthermore give you the option of conveniently navigating through the
information provided in the Help menu of COSIMIR® PLC .
COSIMIR® PLC Assistant provides detailed function descriptions and
technical documentation for the individual process models. It also
comprises a sample PLC program for the more complex process models.
The PLC program is created in STEP 7.
All process models can be directly accessed via the graphic navigator.
Adobe Acrobat Reader will need to be installed on your PC to view PDF
documents. The Adobe Acrobat Reader program is available free of
charge and can be downloaded via the Internet address
www.adobe.com.
Our telephone Hotline is available 24 hours, should you have any
queries when installing or commissioning COSIMIR® PLC .
10 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
With COSIMIR® PLC you have also acquired a CD-ROM and these
instructions. We offer two methods for the software installation:
• Network installation with dongle for parallel interface or USB
interface
• Installation with on-line activation.
The system requirements for COSIMIR® PLC are specified.
The system requirements for a PLC programming system are not taken
into consideration. A PLC programming system is required, if you create
your own PLC programs for the process models.
Minimum configuration for COSIMIR® PLC
Processor Pentium II 300 MHz processor or higher
Main memory 128 MB
Hard disk space 800 MB available
Operating system Windows 98; Windows NT/2000/XP;
Microsoft Internet Explorer
Version 5.0 or later
Graphics card Card with 3D acceleration and OpenGL
support, 32 MB RAM
Monitor 17“ with screen resolution 1024 x 768 Pixel
Interfaces Parallel or USB interface for dongle with
network licence
optional: serial interface for connection to
PLC
Additional Adobe Acrobat Reader Version 6.0 or later
2. This is how you install COSIMIR® PLC
2.1
System requirements
2. This is how you install COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 11
Recommended configuration for COSIMIR® PLC
Processor Pentium IV 1 GHz processor
Main memory 256 MB
Hard disk space 800 MB available
Operating system Windows 98; Windows NT/2000/XP;
Microsoft Internet Explorer
Version 5.0 or later
Graphics card Card with 3D acceleration and OpenGL
support, 64 MB RAM
Monitor 19“ with screen resolution 1024 x 768 Pixel
Interfaces Parallel or USB interface for dongle with
network licence
optional: serial interface for connection to
PLC
Additional Adobe Acrobat Reader Version 6.0 or later
2. This is how you install COSIMIR® PLC
12 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
The initial steps for installation:
• Switch on the PC and start up Microsoft Windows.
• Insert the COSIMIR® PLC CD-ROM.
• Click onto Execute in the Start menu.
• Enter d:setup.exe in the input field of the open dialog window.
Confirm this entry with OK.
The start screen of the installation program is now displayed:
Follow the instructions of the installation program. If you are unsure
when answering some of the questions, click onto either Back or
Cancel.
First, you will be familiarised with the licence agreements of Festo
Didactic. You must accept these licence agreements in all instances,
2.2
Installation of COSIMIR®
PLC via on-line activation
Preparing the installation
2. This is how you install COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 13
otherwise it is not possible to continue with the installation. Select
Accept and then click onto the Next button.
2. This is how you install COSIMIR® PLC
14 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
You are then offered the option of installing the software for only one
registered user.
2. This is how you install COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 15
In the following dialog window, you are requested to enter the product
ID. The product ID is a 12-digit number, which you will find on the
reverse side of the CD-ROM sleeve.
If you enter an incorrect product ID, you will receive a message from the
program, requesting you to enter a valid product ID.
2. This is how you install COSIMIR® PLC
16 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
In the window Select Target Folder , define the subdirectory, in which
COSIMIR® PLC is to be installed. We have selected the subdirectory
C:\Programme\didactic\COSIMIR PLC as a default setting for you.
To install the program in a different directory, click onto the Search
button.
You should always select an installation directory, which does not
contain any other versions of COSIMIR®.
You also have the option of specifying a particular program group where
the COSIMIR® PLC symbols are stored. We have specified Festo Didactic
for the program group as a default setting. You can of course rename
this.
Note
2. This is how you install COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 17
COSIMIR® PLC is now ready for installation. Click onto Next to start the
installation.
2. This is how you install COSIMIR® PLC
18 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
The Start window of COSIMIR® PLC:
Carrying out the
installation
2. This is how you install COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 19
You can install COSIMIR® PLC using two different options. These are:
COSIMIR® extensions as well as robot and PLC languages.
We strongly recommend that you accept the preset option.
The following window is displayed if you click onto the Options button
to select the COSIMIR® main program:
2. This is how you install COSIMIR® PLC
20 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
You are now advised of the successful completion of the COSIMIR® PLC
installation. Now click onto Finish.
2. This is how you install COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 21
The installation of COSIMIR® PLC is complete. You now still need to
decide whether you wish to carry out the licence activation immediately
or at a later stage.
Various options are available to you for the activation of your licence:
On-line activation
2. This is how you install COSIMIR® PLC
22 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
We recommend that you use the direct on-line activation as a default
setting.
You can however also carry out the activation from another PC. If you do
not have an Internet connection, you can also request the activation
code via telephone.
This telephone service is available
Monday to Friday from 8:00 h to 22:00 h CET.
You have decided to use direct on-line activation:
You are requested to establish an Internet connection. Having done so,
click onto Next and your licence will then been activated automatically.
The following message will be displayed if direct communication is not
possible due to Internet access protected by a firewall:
2. This is how you install COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 23
The activation code is available on the relevant Internet page.
Highlight the activation code and copy it via the clipboard to the input
field provided for the activation code using Ctrl+C and Ctrl+V.
Activation is complete as soon as you click onto Finish.
2. This is how you install COSIMIR® PLC
24 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
You have selected the option of carrying out the on-line activation from
another PC. The following request is therefore displayed:
Now establish Internet access to the specified Internet address on
another PC. The following window is then displayed:
Indirect activation
2. This is how you install COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 25
Copy the licence code to the relevant input field. Now click onto the
Generate activation code button.
The activation code is now displayed. Copy this code and insert it in the
specified field of your installation computer.
You have decided to request the activation code via telephone:
Contact Festo Didactic via one of the telephone numbers listed. Quote
your licence code and you will then be given the activation code for your
COSIMIR® PLC software.
Enter the activation code in the input field designated for this. The
licence will be activated as soon as you click onto Finish.
Telephone request
2. This is how you install COSIMIR® PLC
26 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
You can save the licence code and the activation code prior to
completing the licence activation via Finish. To do so, click onto the
Print/Copy button.
You are offered various options of saving the licence code and
activation code.
If you have purchased a multiple licence, you will need to activate each
individual installation. You will be given the relevant information during
each activation as to how many licences can still be activated with the
product ID quoted.
The term “network installation” refers primarily to the software licence
allocation. With network installations, the software is made available
via a network and a central licence server.
You will need a green dongle for the network installation. The licences
are allocated dynamically and can be requested from any workstation in
the network up to the maximum number ordered. The licence server is a
computer on the network, which performs the licence allocation. The
dongle needs to be permanently inserted in the parallel or USB port
during the operation of COSIMIR® PLC so that users on the network are
able to permanently access the information of the dongle.
Multiple licence
2.3
Network installation
of COSIMIR® PLC
2. This is how you install COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 27
You also have the option of setting up a local single station licence.
Start the installation as described above. The following start screen is
then displayed:
To set up a single station version, select the second option. The
installation process is effected in the same as described above.
If you have already completed an installation, you can subsequently
make additions to the COSIMIR® PLC installation using the option
Change Components.
Single station
2. This is how you install COSIMIR® PLC
28 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
The software program EzOPC is required if you control the process
models of COSIMIR® PLC via an external PLC. EzOPC effects the
communication between the process model and the external PLC.
This is how you install EzOPC
1. Insert the COSIMIR® PLC CD-ROM.
2. Click onto Execute in the Start menu.
3. Enter d:\EzOPC\ezopc_setup.exe in the input field of the open dialog
window and confirm it with OK.
The start screen of the installation program is now displayed:
4. Follow the instructions of the installation program.
2.4
Installation of the com-
munication program
EzOPC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 29
COSIMIR® PLC consists of functions to support you in the use of the
software program during training.
These include:
• An individual working environment that can be set up on each
student’s PC. This working environment stores user specific data for
COSIMIR® PLC .
• Files with fault settings for a process model can be centrally set up
by instructors and easily copied to the PC workstation of the
students.
The example of the distribution station process model is used to
demonstrate which files belong to a process model and what
information is stored in these files.
The name of the directory for the distribution process model is
DistributingStation.
3. These functions support you with the preparation
of PC workstations for students
3.1
Description of files for a
process model
3. These functions support you with the preparation of PC workstations for students
30 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
File Description
DistributingStation.mod Process model for simulation via the internal S7-PLC.
DistributingStation.ini Initialisations for the process model: This file contains all user
specific settings for the process model such as window
configuration, fault settings, etc.
DistributingStation.prot Protocol of fault localisation: This file is read in the teacher mode
and displayed in the fault log window.
DistributingStation.htm
DistributingStation.xls
DistributingStation.txt
Export of fault log: Changes in the fault localisation and in the fault
log are automatically exported to these files. These files can then for
instance be viewed via Microsoft Internet Explorer or Microsoft
Excel.
DistributingStation.mcf Settings regarding fault setting: This file contains all settings
regarding the activation, start, duration and localisation of a fault. If
this file exists in the process model directory, then it overwrites the
settings in the INI file. If not, then the fault settings stored in the INI
file are used.
User-specific working environments consist in the main of the process
models and files with the user specific data.
User specific data are:
• Window configurations,
• Settings for the process model,
• Settings regarding fault setting,
• Protocol of fault localisation.
In order to create a user-specific working environment, the process
models are saved to a separate directory on the PC. Any user specific
data is then also stored in this directory.
3.2
Creating a user-specific
work environment
3. These functions support you with the preparation of PC workstations for students
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 31
For example, to set up the working environment for three different users
on one PC, you will need to copy the process models into three different
directories. Each user will then be working with “his/her own” directory,
which corresponds to the user’s working environment. The user loads
the process models with which he/she is working in COSIMIR® PLC from
„his/her“ directory.
COSIMIR® PLC supports you with the setting up of user specific working
environments. Use the setup program SetupSamples.exe for this.
The SetupSamples.exe program
The SetupSamples.exe program enables you to create the user specific
working environments for COSIMIR® PLC on a PC.
• The setup program SetupSamles.exe installs the process models
assistant-aided on a computer or a network path.
• The choice of installation directory is arbitrary.
• No administrator rights on the computer are required.
This is how you create a user specific working environment for
COSIMIR® PLC
1. Insert the COSIMIR® PLC CD-ROM.
2. Click onto Execute in the Start menu.
3. Enter d: SetupSamles.exe in the input field of the open dialog
window and confirm this with OK.
The start screen of the installation program is now displayed.
3. These functions support you with the preparation of PC workstations for students
32 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
4. Follow the instructions of the installation program. Select the
desired working directory as the installation directory.
5. If users want to work in their working environment, then they are to
start COSIMIR® PLC . The process models that users are to work with
must always be loaded from the user’s working directory.
You can load a process model from any working directory by
selecting Open in the File menu and navigating through your
working directory and selecting the desired process model.
Please note that file names of process models to be controlled via
an external PLC always end with the identifier OPC. File names of
process models controlled via the internal PLC do not end with the
identifier OPC.
3. These functions support you with the preparation of PC workstations for students
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 33
You can also start the setup program SetupSamples.exe from the
Windows command line (cmd.exe). To install several working
environments from COSIMIR® PLC on one PC, you have the option of
carrying out the installation by means of a batch file. The batch file is
called up via the Windows command line.
Excerpt from a batch file:
SetupSamples.exe /S –XD:C:\CosimirPLC\Student1
SetupSamples.exe /S –XD:C:\CosimirPLC\Student2
SetupSamples.exe /S –XD:C:\CosimirPLC\Student3
Files with fault settings for a process model can be created centrally by
teaching staff and copied to the PC workstations of students in a simple
manner.
Note
3.3
Creating files with fault
settings for a process
model
3. These functions support you with the preparation of PC workstations for students
34 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
This is how you create a file centrally with fault settings for a process
model:
1. Start COSIMIR® PLC .
2. Load the desired process model, e.g. the process model Distribution
Station. The process model is to be controlled via the internal PLC
and the file name therefore does not include the identifier OPC.
3. Open the Fault Setting window by clicking onto Fault Setting in the
Execute menu.
4. The Fault Setting window opens once you have entered the
password.
5. Now set a fault – for example for the PLC input 1B1.
6. Activate the context sensitive menu via the right mouse button and
select the option Export.
3. These functions support you with the preparation of PC workstations for students
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 35
7. The faults set for the process model DistributingStation.mod have
been exported to the file DistributingStation.mcf. You will find this
file in the same directory, in which the process model loaded at the
time is also stored.
3. These functions support you with the preparation of PC workstations for students
36 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
8. Now copy the file with the fault settings to the user specific working
environments. The user specific working environments are those
directories, where only the process models have been installed.
Select the directory in which the relevant process model is stored as
directory, in this case the Distribution Station process model.
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 37
COSIMIR® PLC comprises the following:
• The simulation software COSIMIR® PLC
• The communication software EzOPC
• The on-line COSIMIR® Help
• The on-line COSIMIR® PLC Assistant
• A PDF file with information regarding EzOPC
• A manual
COSIMIR® PLC is a PC-based 3D simulation system with preassembled
process models.
Internal S7 PLC
OPC client
EzOPC (OPC server)
EasyPort
ExternalPLC
S7-PLCSIM
Operatingfunctions
COSIMIRassistant
COSIMIRhelp
Process models
MC7-Code
Component parts of COSIMIR® PLC
4. The COSIMIR® PLC system
4.1
Overview of
COSIMIR® PLC
4. The COSIMIR® PLC system
38 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
The following are required to simulate the operation of a process:
• A PLC and PLC program to control the process,
• The simulation to simulate the behaviour of the process. This
simulation ensures for example, that cylinders move and sensors
are activated.
Sample PLC programs are available for complex process models. These
PLC programs define a possible process control system. You can of
course create new PLC programs that generate a different process
execution.
When loading a process model, the sample PLC program is
automatically downloaded at the same time, provided that it exists. The
PLC program is executed via a SIMATIC S7 simulator. This S7 simulator
is a component part of COSIMIR® PLC . The integrated
S7 simulator is also referred to as the internal PLC.
Once the process model has been loaded, the process can be simulated
immediately.
The advantage with this is that you can familiarise yourself with,
activate and monitor the process. Plus there is no need for you to have
created a PLC program beforehand.
One particular additional function offered by COSIMIR® PLC is the
possibility of simulating faults, whereby you can set typical faults in a
process model. The following can for example be causes of malfunction:
A mechanically displaced sensor, a cable break or failure of an entire
module. The cause of the fault must be found by means of systematic
fault finding and eliminated.
One of the main focal points of COSIMIR® PLC is the monitoring and
analysis of processes and elimination of faults.
Another focal point is the creation of your own PLC programs for the
process models. These PLC programs are loaded to an external PLC and
COSIMIR® PLC exchanges the input/output signals with the external PLC
via the OPC interface.
4. The COSIMIR® PLC system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 39
The following can be used as external PLCs
• Any actual PLC
• The Soft PLC SIMATIC S7-PLCSIM
COSIMIR® PLC requires the software program EzOPC for connection to
an external PLC. The OPC server EzOPC communicates with any PLC via
the EasyPort interface.
.
Please note: EzOPC is not installed automatically with the software
program COSIMIR® PLC . If required, this program is to be installed from
the DC-ROM provided.
The process models are realistic replicas of actual working stations and
modules.
Each process model comprises two work cells. The work cell whose file
name does not have the ending OPC is controlled via an internal PLC. If
you wish to control the process model via an external PLC, you need to
select the process model with the file name ending in OPC.
Process model Description File name
Processing Station
The process model represents a
simulation of the MPS Processing
Station of Festo Didactic. In this
work cell, workpieces are to be
tested, processed and transferred
to the adjacent station. A sample
PLC program is available for this
process model.
ProcessingStation.mod
ProcessingStation(OPC).mod
4.2
The process models
of COSIMIR® PLC
4. The COSIMIR® PLC system
40 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Process model Description File name
Handling Station
The process model represents a
simulation of the Festo Didactic
MPS Handling Station. In this
work cell, workpieces are to be
removed from a retainer and,
depending on the results of
material testing, deposited on a
slide. A sample PLC program is
available for this process model.
HandlingStation.mod
HandlingStation(OPC).mod
Stacker Store Station
The process model represents a
simulation of the Festo Didactic
Stacker Store. In this work cell,
workpieces are to be put into and
removed from storage. A sample
PLC program is available for this
process model.
StoreWorkCell.mod
4. The COSIMIR® PLC system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 41
Process model Description File name
Testing Station
The process model represents a
simulation of the Festo Didactic
MPS Testing Station. In this work
cell, the material characteristics
of the workpieces is to be
determined and the workpiece
height checked. Depending on
the test result, the workpiece is
either ejected or transferred to
the adjacent station. A sample
PLC program is available for this
process model.
TestingStation.mod
TestingStation(OPC).mod
Buffer Station
The process model represents a
simulation of the Festo Didactic
MPS Buffer Station. In this work
cell, workpieces are to be
transported, buffered and
separated out. A sample PLC
program is available for this
process model.
BufferStation.mod
BufferStation(OPC).mod
Sorting Station
The process model represents a
simulation of the Festo Didactic
MPS Sorting Station. In this
workcell, workpieces are to be
sorted according to material and
colour. A sample PLC program is
available for this process model.
SortingStation.mod
SortingStation(OPC).mod
4. The COSIMIR® PLC system
42 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Process model Description File name
Distribution Station
The process model represents a
simultation of the Festo Didactic
MPS Distribution Station. In this
work cell, workpieces are to be
separated out and transferred to
the adjacent station. A sample
PLC program is available for this
process model.
DistributingStation.mod
DistributingStation(OPC).mod
4. The COSIMIR® PLC system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 43
Process model Description File name
Rotary Indexing Table Module
The process model represents a
simulation of the Festo Didactic
MPS Rotary Indexing Table
module. In this work cell,
workpieces are to be tested and
polished in two parallel
sequences.
RotaryTable.mod
RotaryTable(OPC).mod
Stacking Magazine Module
The process model represents a
simulation of the Festo Didactic
MPS Stacking Magazine module.
In this work cell, workpieces are
to be separated out from the
magazine.
StackMagazine.mod
StackMagazine(OPC).mod
Changer Module
The process model represents a
simulation of the Festo Didactic
MPS Changer module. In this
work cell, workpieces are to be
picked up by a vacuum suction
cup and transferred by means of a
semi-rotary actuator.
ChangerModule.mod
ChangerModule(OPC).mod
4. The COSIMIR® PLC system
44 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
The PLC integrated into COSIMIR® PLC is a SIMATIC S7 simulator. The S7
simulator can execute LDR, FCH and STL programs created in STEP 7.
The internal PLC executes the sample PLC programs provided for the
process models and enables you to immediately simulate the
processes.
Detailed information regarding the function scope of the internal PLC is
available via the COSIMIR® on-line Help.
4.3
Controlling the process
models via internal PLC
4. The COSIMIR® PLC system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 45
If you are creating and testing your own PLC programs, we recommend
that you download the programs to an external PLC and execute them
from there. The advantage of this is that you can choose the PLC and
programming system of your choice. Also, the testing and diagnostic
functions designated by the program for this purpose are available to
you for fault finding in the PLC program. This includes the status display
of PLC input/outputs and variables, the on-line display of the PLC
program and also the read-out of machine statuses.
If you are using the Soft PLC7-PLCSIM as external PLC, you do not
require any additional hardware components.
Information exchange with configuration via external Soft PLC S7-PLCSIM
4.4
Controlling the process
models via external PLC
4. The COSIMIR® PLC system
46 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
If you are using a hardware PLC as external PLC, you will require
EasyPort and the data cable for the exchange of input/output signals.
EasyPort transmits the input/output signals of the PLC to the OPC
server ExOPC via the serial interface of the PC and the OPC server
passes on the data to the process model simulation. Conversely, the
statuses of sensors and actuators are communicated from the process
model to the external PLC.
Information exchange with configuration via external hardware PLC
4. The COSIMIR® PLC system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 47
The dialog window for fault setting is password protected. Only
instructors have access to this dialog.
A list of typical faults is available for each process model, from which
you can select one or several faults.
The exercise for students is to identify and describe the fault within the
process and to then determine the cause of it. The students then enter
the suspected fault in the dialog window for fault elimination. If the fault
has been correctly identified, the process will then function correctly.
The entries in the dialog window for fault elimination are logged and can
be seen by instructors and trainers.
4.5
Functions for fault setting
in the process model
4. The COSIMIR® PLC system
48 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
COSIMIR® PLC offers you various options of monitoring and analysing
the execution of a process.
As soon as the simulation of a process model is active and a PLC is
controlling the process, you can activate and visually monitor progress.
The process is controlled by means of the keys and switches on the
control console.
4.6
Functions for the analysis
of process models
4. The COSIMIR® PLC system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 49
• The electrical status of the process components is displayed by LEDs
on the sensors and valves.
• If pressure is applied to a cylinder connection, the connection is
highlighed in blue. The pneumatic tubing itself is not simulated.
• The statuses of the PLC inputs/outputs are shown in separate
windows.
• An overview of all process statuses and process operations is
provided in the Manual Operation window.
If you want to run the process step-by-step, you need to use the Manual
Operation as a tool to control the process. You can stop the process at
defined points by setting breakpoints.
In the absence of an active PLC program during process model
simulation, you can use the Manual Operation window to activate
individual process activities. This will enable you to, for instance,
control the movement of a cylinder or switch on or off an electrical
motor.
50 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
This chapter describes the main control functions of COSIMIR® PLC . MS
Windows programs provides various options for activating commands.
In this account, commands are initiated via the options in the menu bar.
You can of course also use the symbols bar, appropriate key
combinations or the context sensitive menu via the right mouse button.
Detailed information regarding the use of all options in COSIMIR® PLC is
available via the on-line Help for this software package.
Prior to loading a process model, you will need to decide whether the
process model is to be controlled via the internal or via an external PLC.
The file names of process models to be activated via an external PLC
end with the identifier OPC.
You can load the process model with the help of COSIMIR® PLC
Assistant or a command in the menu bar.
5. Important control functions of COSIMIR® PLC
5.1
Loading a process model
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 51
This is how you load a process model via COSIMIR® PLC Assistant
1. Start COSIMIR® PLC .
Once COSIMIR® PLC is started, both the View window and the Help
window are displayed.
5. Important control functions of COSIMIR® PLC
52 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
2. Select the desired process model, for example the process model
Distribution, controlled via the internal PLC.
The process model is opened by clicking onto Open Distribution (for
internal PLC).
Please note:
A click onto the picture or the title of the process model will take you to
COSIMIR® PLC Assistant, where a function description and technical
documentation regarding the process model are at your disposal.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 53
3. The process model for the Distribution station is loaded and is
displayed in the View window. In addition, you will also find the
status of the PLC input/outputs in the Inputs and Outputs windows.
5. Important control functions of COSIMIR® PLC
54 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
A dialog window is displayed via File download, if you open a process
model the first time via the on-line Help.
Note
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 55
If you select the option Open File from your Current Position, you need
to deactivate Always Confirm Open Files of this Type and click OK.
5. Important control functions of COSIMIR® PLC
56 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
This is how you load a process model by activating a menu command
1. Click onto Open in the File menu.
The process models are filed under the default setting
c:\Programme\didactic\COSIMIR PLC \samples.
Each process model is in its own subdirectory.
2. Select the desired process model, for example the process model
Distribution, controlled via the internal PLC. To do so, open the
subdirectdory DistributingStation:
Highlight the directory DistributingStation and click onto the Open
button.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 57
3. Highlight the file DistributingStation.mod and click onto the Open
button.
5. Important control functions of COSIMIR® PLC
58 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
4. The process model for the Distribution station is now loaded and is
displayed in the View window.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 59
Once loaded, the process is displayed, but simulation is not active.
If a process model, controlled via the internal S7 PLC, has been loaded,
a sample PLC program will have been downloaded to the internal S7 PC
at the same time.
This is essential to facilitate the operation of a process model.
As soon as simulation is active, you can monitor the visual simulation
and as such the function sequence of the process model in the activity
window.
5.2
Simulating a process
model
5. Important control functions of COSIMIR® PLC
60 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Certain information is always available to you.
In the header you will see the file name with path details of the process
model loaded.
The status line informs you of the operational status of the process
model:
The field to the far left shows whether simulation is active or stopped.
• Stopped:
Simulation mode is not active. The process model is not simulated.
• Cycle:
The process model is simulated.
• Sequence:
The process model is simulated.
The field to the right indicates the simulation time.
In COSIMIR® PLC , both simulation modes Cycle and Sequence are
identical.
Note
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 61
This is how you switch simulation on and off again
1. Click onto Start in the Execute menu.
Simulation is active. In the status bar, the simulation mode is
displayed via Sequence.
Alternatively, you can also activate simulation via the menu option
Start Cycle or via the Stopped button in the status bar.
2. You can stop simulation by clicking onto Stop in the Execute menu.
Alternatively, you can also click onto the Cycle field.
5. Important control functions of COSIMIR® PLC
62 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
A process model controlled via a PLC program is operated via the keys
and switches of the control console. To do so, simulation must be
active. The simulation status can be established via the information in
the status bar.
5.3
Displaying and operating
a process model
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 63
This is how you operate a process model controlled via the sample PLC
program
1. Start simulation by clicking onto Start in the Execute menu.
2. The illuminated Reset button now requests the Reset function.
Failing this, put the process model into the initial position. To do so,
activate the simulation. Then click onto the command Work Cell
Initial Position in the Processing menu.
Now restart simulation.
3. Carry out the Reset function by clicking onto the Reset button.
4. The illuminated Start button indicates that the process model is in
the initial position and the start condition is fulfilled.
5. Make sure that workpieces are available. For the process model
Distribution, you fill the magazine with workpiece by clicking onto
the different coloured symbolic workpieces on the slotted assembly
board.
6. Start the cycle by clicking onto the Start button.
If the process model is to be controlled via your own PLC program, then
you will know how the process and operation are defined.
If the process model is not controlled via a PLC program, then you can
manually activate specific actuators of the process. You will need the
functions of the Manual Operation window for this.
This is how the status of the process model is displayed
• The electrical status of the process components is displayed via the
LEDs on the sensors and valves.
• If pressure is applied to a cylinder connection, then this connection
is highlighted in blue.
The pneumatic tubing itself is not shown.
• The status of the PLC signals is displayed in the Inputs and Outputs
windows.
• The Manual Operation window provides an overview of all process
statuses and process events.
5. Important control functions of COSIMIR® PLC
64 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
• The designation of components is shown by clicking onto the
connection or LED of a process component. This designation is
identical to the designation in the circuit diagram.
An exception to this are the designations of compressed air
connections. These pertain to the valves which supply the
compressed air connections with air.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 65
The perspective view of a process model is freely adjustable and you
can turn, move, enlarge or minimise the process model representation
by means of a few central commands.
5.4
Changing the view of a
process model
5. Important control functions of COSIMIR® PLC
66 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
The perspective view is defined by the coordinates of the viewer (=
angle) and a reference point of the process model (= centre).
Z
Reference pointAngleTurn
Y
X
Definition of perspective view
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 67
This is how you move the process model
1. Click onto the Move command in the View menu.
This changes the mouse pointer into a small coordinate system,
which indicates the direction in which the angle and reference point
can be moved. A dashed arrow means that it is not possible to move
in the respective direction.
2. Hold down the left mouse button.
3. Move the mouse pointer in Z- or X-direction.
4. Release the mouse pointer again. The view will then change
accordingly.
You can also activate the Move command by holding down the Shift key
and pressing the left mouse button.
This is how you turn the process model
1. Click onto Turn in the View menu.
The mouse pointer now changes into a small coordinate system,
which indicates the direction in which the angle and reference point
can be moved. A dashed arrow means that it is not possible to move
in the respective direction.
2. Hold down the left mouse button.
3. Move the mouse pointer in Z-or X-direction.
4. Release the mouse pointer again.
The view will then change accordingly.
You can also activate the Turn command by holding down the Ctrl key
and then pressing the left mouse button.
This is how you enlarge or minimise the view
1. Activate the Zoom command in the View menu.
The mouse pointer now changes into two squares.
2. To enlarge the view, hold down the left mouse button and move the
mouse pointer in the direction of the arrow.
5. Important control functions of COSIMIR® PLC
68 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
3. To reduce the view, hold down the left mouse button and move the
mouse pointer in the opposite direction of the arrow.
You can also activate the Zoom command by holding down the Shift +
Ctrl key combination and then pressing the left mouse button.
This is how you enlarge a particular section
1. Position the mouse pointer on a corner of the section.
2. Hold down the Shift + Ctrl key combination.
3. Press the right mouse button and move the mouse. A frame is then
displayed.
4. Place the frame around the section you would like to enlarge by
moving the mouse.
5. Release the right mouse button. The view is now enlarged.
This is how you enlarge the view
Click onto Zoom-In in the View menu. The image is now enlarged to
125%.
This is how you minimise the view
Click onto Zoom-Out in the View menu. The picture is minimised to
80%.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 69
The Inputs and Outputs windows indicate which signals are applied at
the inputs and outputs of the PLC. 0-signals are displayed in red and
1-signals in green. If the input or output signal is forced, the value is
shown in angle brackets, e.g. <1>.
This is how you open the Inputs window
Click onto the option Inputs/Outputs in the Options menu and select
Display Inputs.
So that you know which process signal you are dealing with, the signal
names include the relevant designation from the circuit diagrams.
Example: STATION_1B2: PLC input, which is connected to the sensor
1B2.
This is how you open the Outputs window
Click onto the option Inputs/Outputs in the Options menu and select
Display Outputs.
So that you know which process signals you are dealing with, the signal
names contain the relevant designations from the circuit diagrams.
Example: STATION_1Y1: PLC output, which is connected to the valve
coil 1Y1.
5.5
The Inputs and Outputs
windows
5. Important control functions of COSIMIR® PLC
70 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
You can however also open the Inputs and Outputs windows via Work
Areas in the Windows menu, where you will often find the required
window combinations.
The Manual Operation window offers various functions
• Display of process statuses and process activities,
• Controlling individual actuators of the process model,
• Setting breakpoints in the process model simulation.
In the lefthand section of the window you can see the process activities.
These include mainly the actuation of valves. An applied 1-signal is
represented by a red illuminated LED.
In the righthand section of the window you can monitor all process
statuses.
Process statuses include the status of the sensor and valve coils. Here,
1-signals are represented by a green illuminated LED.
The signal statuses are also shown in the Value column. If the signal is
forced, the value is shown in angle brackets. If the Value column is now
shown, activate the item in the context sensitive menu via the right
mouse button.
Notes
5.6
The Manual Operation
window
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 71
The following additional information is displayedi: If a signal status has
changed since the last simulation cycle, then the respective line is
highlighted in colour. Process activities are shown in red and process
statuses in green. This method enables you to easily identify and track
any signals which have changed.
This is how you open the Manual Operation window
In the Execute menu, click onto Manual Operation.
Alternatively , open the window by clicking onto Manual Operation
under Work Areas in the Windows menu.
This is how you control individual actuators in the process model
If you want to actuate individual actuators of a process model manually,
we recommend that you disconnect the process model from the PLC.
Only those commands will then be executed which have been initiated
via manual operation since the PLC program is no longer active.
If you wish to terminate manual operation and control the process
model via a PLC program once again, you will need to reconnect the
process model to the PLC.
5. Important control functions of COSIMIR® PLC
72 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
1. Make sure that simulation is stopped.
2. Isolate the process model from the PLC.
Move the mouse pointer to the left section of the Manual Operation
window and the process activities. Press the right mouse button to
open the context sensitive menu and select Disconnect Controllers.
Or:Click onto the left section of the Manual Operation window and
open the context sensitive menu via the right mouse button and
then select Disconnect Controllers.
3. Start the simulation.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 73
4. Double click onto the process activity line you wish to execute. The
double click causes the signal to change.
If you double click onto a line with a valve activation, this causes the
value of the respective valve coil to change. If the value 0 is applied,
this will be set to 1 or vice versa. The double click therefore has a
toggle function.
Please note: To switch a valve with two valve coils to a particular
position, the appropriate electrical signal must be applied to both
valve coils.
5. Stop simulation, if you wish to end Manual Operation.
5. Important control functions of COSIMIR® PLC
74 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
6. To control the process model via a PLC program again, move the
mouse pointer to the left section of the Manual Operation window
to the process activities. Now press the right mouse button to open
the context sensitive menu and select Restore I/O Connections.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 75
This is how you set breakpoints during the operation of the process
model
To stop the process model operation at defined points, you will need to
set breakpoints in the process model simulation. You can stop the
process run whenever the value of a process signal is changing.
Breakpoints merely influence process model simulation; the PLC
program for the control of the process model remains unaffected. If a
breakpoint is set at a signal, this causes the process model simulation
to stop when the value of the signal changes. The changed value is
transmitted to the PLC as soon as simulation is restarted.
1. Make sure that a process model is loaded.
2. Start the process model simulation and establish that the process
model is controlled via a PLC program.
3. Open the Manual Operation window. To do so, click onto Manual
Operation in the Execute menu.
5. Important control functions of COSIMIR® PLC
76 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
4. Click onto the line of the desired process activity. In this case, for
example, line 2 to control valve coil 1Y1 for the magazine ejector.
Click onto the right mouse button to open the context sensitive
menu and select Stop at Value Change.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 77
5. The Stop sign in the line in the Manual Operation window indicates
that a breakpoint is set at this signal.
5. Important control functions of COSIMIR® PLC
78 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
6. Activate the process. As soon as the PLC generates a 1-signal at the
valve coil, simulation stops. You can follow the simulation status in
the status bar.
7. If you restart simulation of the process model, this causes the
process run to continue and the magazine ejector to eject a
workpiece.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 79
8. To delete the breakpoint, click onto the line with the breakpoint with
the right mouse button. This opens the context sensitive menu of
the right mouse button. Select Stop at Value Change. This command
is realised in the form of a toggle function. The breakpoint is
removed. Alternatively, you can select the command Delete all
Stops.
Please note that you can also set breakpoints at signals in the Process
Status window section.
5. Important control functions of COSIMIR® PLC
80 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
This is how you control the process model step-by-step
If you want to execute the process stepwise, then use the Manual
Operation window as a tool to control simulation. You can stop the
process at defined points by setting breakpoints.
To execute the process step-by-step, set breakpoints against all process
activities. In this way, the process will be stopped whenever an actuator
changes its status.
1. Make sure that a process model is loaded.
2. Start the process model simulation and make sure that the process
model is controlled via a PLC program.
3. Open the Manual Operation window. To do so, click onto Manual
Operation in the Execute menu.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 81
4. Under Process Activities, highlight all lines containing signals for
valve coils by pressing the Ctrl key and clicking onto the desired
lines with the left mouse button.
Open the context sensitive menu via the right mouse button and
select Stop at Value Change.
5. Important control functions of COSIMIR® PLC
82 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
5. All lines with valve coils now indicate breakpoints.
6. Control the process by using the keys and switches of the control
console. Whenever the status of a process signal changes,
simulation stops. The process is continued if you restart simulation.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 83
7. To remove the breakpoints again, open the context sensitive menu
via the right mouse button and select Delete all Stops.
Please note that you can also set breakpoints at signals in the Process
Status window section.
5. Important control functions of COSIMIR® PLC
84 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
The internal S7 simulator interprets executable S7 programs. A sample
PLC program for S7-300 is available for each of the more complex
process models. When you load a model, the respective S7 program is
also downloaded. You can exchange this S7 program with another S7
program, if required.
Only complete project files with the file extension S7P can be
downloaded. The project will need to have been created via the SIMATIC
Manager and must be in accordance with the Siemens MC7 code at
binary level.
5.7
Controlling a process
model via the internal
S7 PLC
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 85
This is how you control a process model via the relevant sample PLC
program
1. Click onto Open in the File menu.
2. Load the desired process model, for example the Distribution
process model. The file name of the model is
DistributingStation.mod.
The process models are stored under a default setting
c:\Programme\didactic\COSIMIR PLC \samples.
When a process model is loaded, the respective S7 program is also
downloaded.
5. Important control functions of COSIMIR® PLC
86 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
3. As soon as simulation of the process model is started, the execution
of the S7 is also started.
To do so, click onto Start in the Execute menu.
This is how you control a process model via a newly created S7 PLC
program
1. Load the desired process model. The process model is to be
controlled via the internal PLC. The file names of process models for
the internal PLC do not end in OPC.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 87
2. Make sure that simulation has stopped.
3. Select Open in the File menu to open the Open File window.
4. Under File Type, select S7 Project (*.S7P).
All files of this format available in the current directory are
displayed.
5. Important control functions of COSIMIR® PLC
88 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
5. Navigate to the directory which contains your S7 project.
Select the required S7 project and click onto the Open button.
6. If the project you have selected contains several S7 programs, then
select one for simulation and confirm your choice with OK.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 89
7. Start the process model simulation. Select Start in the Execute
menu. As soon as the simulation of the process model is started, the
internal S7 simulator is also started and the loaded PLC program is
executed.
This is how you estalish which S7 program is currently loaded
1. Click onto the S7 Program Manager option in the Execute menu.
2. The name and the structure of the PLC program are displayed in a
clearly set out tree structure.
The PLC program may consist of the following blocks: Organisation
blocks, function blocks, data blocks, functions and system
functions.
5. Important control functions of COSIMIR® PLC
90 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
3. Click onto the +-symbol to display the PLC program.
You can view the contents of a block by clicking onto a block.
4. In the absence of a loaded PLC program, the window S7 Program
Manager looks as follows:
Further information regarding the display of S7 programs in STL or for
the display and use of timing diagrams is available via the on-line Help.
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This is how the sample programs are filed on the computer
1. Select Open in the File menu to open the Open File window.
2. Under File Type, select S7 Project (*.S7P).
All the files in this format available in the current directory will be
displayed.
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92 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
3. Navigate to the directory c:\Programme\didactic\COSIMIR
PLC\samples\S7\MPSC. This directory contains the S7 project with
all the sample PLC programs for the stations, provided that you have
transfered all the preset directories when installing COSIMIR® PLC .
The sample program for the stacker store is stored in the Store
subdirectory.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 93
4. Select the S7 project and click onto the Open button.
The program name provides information about the PLC program and the
process model to which it belongs:
• The initial digit corresponds to the station number.
• The two letters after this digit designate the station:
DI: Distribution station
TE: Testing station
PR: Processing station
HA: Handling station
BU: Buffer station
SO: Sorting station
• The letters beginning with underscore designate the programming
language of the PLC program:
AS: Programming language GRAPH,
KFA: Programming languages LDR, FCH and STL,
KFAFF: Programming languages LDR, FCH and STL. The step
structure of the process activity is simulated with flipflops.
Please note that the internal S7 PLC can only execute LDR, FCH or STL
programs.
5. Important control functions of COSIMIR® PLC
94 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
S7-PLCSIM is a Soft PLC, which executes the PLC programs created in
STEP 7. Within STEP 7, comprehensive testing and diagnostic functions
are available to you for fault finding in the PLC program. They include,
for instance, the status display of variables or the on-line display of the
PLC program. You can make use of these functions when creating the
PLC program for a process model in STEP 7 and subsequently when
testing the PLC program during interaction with the process model.
The exchange of the PLC input/output signals between the process
model simulation and the Soft PLC S7-PLCSIM is effected via the EzOPC
program. EzOPC must be installed on your computer. Should this not be
the case, you will need to carry out the installation of the COSIMIR® PLC
CD-ROM now.
5.8
Controlling a process
model via the external
Soft PLC S7-PLCSIM
5. Important control functions of COSIMIR® PLC
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Following successful installation, EzOPC is automatically called up by
COSIMIR PLC as soon as you start the process model simulation.
The following requirements must be fulfilled in order for the PLC
input/output signals to be correctly exchanged:
• When EzOPC is started, both communication users – S7-PLCSIM and
the process model simulation- must already be active. Only then can
EzOPC set up the communication link to both stations.
• The EzOPC must be correctly configured for the data exchange.
Therefore check the configuration as soon as EzOPC is started.
Configuration of EzOPC for data exchange with S7-PLCSIM
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96 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
This is how you control a process model with S7-PLCSIM
1. Start STEP 7 or the STEP 7 Manager and open the required
S7 project.
2. Start S7 PLCSIM by clicking onto Simulate Modules under Options.
5. Important control functions of COSIMIR® PLC
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3. The S7-PLCSIM window now opens.
4. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto
the MRES button in the CPU 300/400 window.
5. Important control functions of COSIMIR® PLC
98 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
5. Download the desired PLC program in S7-PLCSIM by highlighting the
Modules folder. Then click onto Download in the menu Target
System.
6. Load the appropriate process model in COSIMIR® PLC . The file name
of the process model must end in OPC, since it is to be controlled via
the external PLC S7-PLCSIM.
5. Important control functions of COSIMIR® PLC
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7. Start the process model simulation by clicking onto Start under
Execute.
As soon as simulation starts, the EzOPC program is automatically
called up and you will see this from the item EzOPC displayed in the
Start bar.
If EzOPC is not called up, you will need to check whether the
program is installed. Failing this, now carry out the installation.
When EzOPC is started, both communication users - S7-PLCSIM and the
process model simulation – must already be active. Only then are the
communication links correctly set up.
Note
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100 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
8. Click onto the EzOPC button in the Start bar. This opens the EzOPC
window, where you configure the communication between
COSIMIR® PLC and S7-PLCSIM.
The EasyPort D16 interface is crossed out. This indicates that the
communication link between EasyPort and EzOPC does not exist.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 101
9. Click onto Communication Setup under Configuration.
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102 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
10. The window Communication Setup is now displayed.
5. Important control functions of COSIMIR® PLC
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11. Carry out the necessary settings.
Select Not Connected in the EasyPort section for EasyPort 1.
Now select Installed in the section PLCSIM for Step 7 PLCSIM V5.x.
Accept the preset values for Start Byte and End Byte without
changing them, although only the first four bytes are required.
In the section VirtualPLC, select PLCSIM for Connect VirtualPLC to:
and confirm the settings with OK.
5. Important control functions of COSIMIR® PLC
104 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
12. The changes require EzOPC to be restarted. Acknowledge this
message with OK.
13. Close the EzOPC program and restart it.
You will find EzOPC under the default setting Programs � Festo
Didactic � EzOPC V4.9.2 .
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 105
14. EzOPC displays the new configuration:
– EzOPC does not use the serial interface.
– EzOPC has set up a communication link with S7-PLCSIM. The data
bytes from S7-PLCSIM shown are exchanged.
15. Minimise the EzOPC window.
16. Make sure that the process model simulation in COSIMIR® PLC is
active.
5. Important control functions of COSIMIR® PLC
106 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
17. Start S7-PLCSIM by clicking onto the box next to RUN in the window
CPU 300/400. The LED for RUN should now start flashing.
18. Operate the process model as planned and programmed in the PLC
program.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 107
19. If faults still exist in the PLC program, then the on-line
representation in STEP 7 will provide you with excellent support
during fault finding. To do so, call up the program block in which you
suspect the fault. Then click onto Monitor in the Test menu. You can
now monitor in parallel with simulation, which PLC program sections
are or are not being executed.
5. Important control functions of COSIMIR® PLC
108 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
If you are creating and testing your own PLC program, we recommend
that you load the programs to an external PLC and have these executed
from there.
You can use the Soft PLC S7-PLC SIM as external PLC, if you are
programming in STEP 7, in which case you will not require any
additional hardware components.
You can however also use any other control or programming system, in
which case you download the PLC program to your hardware PLC. The
exchange of the PLC input/output signals between the process model
simulation and your external PLC is effected via the serial interface of
the PC and via the EasyPort interface. Also included in the exchange of
process signals is the EzOPC program.
The advantage of this configuration is that you can use the PLC and
programming system of your choice. Also available for fault finding in
the PLC program are the testing and diagnostic functions intended for
this purpose in the programming system.
We recommend that you install the simulation software COSIMIR® PLC
and the PLC programming system on different computers.
5.9
Controlling a process
model via an external PLC
5. Important control functions of COSIMIR® PLC
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Possible configuration with a hardware PLC and two PCs
5. Important control functions of COSIMIR® PLC
110 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
However, you can also choose a different configuration and install the
two software packages on one PC. Your PC will need to be equipped
with two serial interfaces if you intend to make use of the testing and
diagnostic functions during the process model simulation .
The following can be used as EasyPort interface:
• EasyPort D16 interface box for 16 digital I/O (Order No.. 1676 121)
The following data cables are required:
• PC data cable RS232 (Order No. 162 305)
• For PLC EduTrainer of Festo Didactic: I/O data cable with SysLink
plugs at both ends to IEEE 488, cross paired (Order No.. 167 106)
• For any PLC: I/O data cable with SysLink plug at one end to IEEE 488
and open cable end sleeves (Order No. 167 122)
The EzOPC program
The EzOPC program organises the exchange of PLC input/output signals
between the process model simulation and the external PLC. EzOPC
does not access the external PLC signals directly, but via the EasyPort
interface.
EzOPC must be installed on your computer. If this is not the case, you
will need to install the COSIMIR PLC CD-ROM now. Once the installation
has been successfully completed, EzOPC will be automatically called up
by COSIMIR PLC as soon as you start the process model simulation.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 111
The following requirements must be fulfilled in order for the PLC
input/output signals to be correctly exchanged:
• When starting EzOPC, both communication users – EasyPort and the
process model simulation - must be active. Only then can EzOPC set
up the communication link to the two users.
In the case of EasyPort this means that EasyPort must be connected
to the PC via the serial interface and voltage applied to EasyPort.
• The EzOPC program must be correctly configured for the data
exchange. Therefore check the configuration as soon as EzOPC is
started.
Configuration of EzOPC for data exchange with an external PLC via EasyPort
5. Important control functions of COSIMIR® PLC
112 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
This is how you control a process model via an external PLC
1. Connect the PC with COSIMIR® PLC to the external PLC via the
EasyPort interface.
– The data cable with Order No. 162 305 connects the serial
interface of the PC to the serial interface RS232 of EasyPort.
– The PLC input/output signals for the process are applied at port 1
of EasyPort.
– The PLC input/output signals for the control console are
transmitted via port 2.
For the DIP switches under Mode at EasyPort, select the following
setting: 1 ON, 2 OFF, 3 OFF.
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Configuration with PLC EduTrainer
5. Important control functions of COSIMIR® PLC
114 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Configuration with PLC board
5. Important control functions of COSIMIR® PLC
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2. Switch on the power supply for EasyPort.
3. Load the desired process model to COSIMIR® PLC . The file name of
the process model must have the ending OPC, since it is to be
controlled via an external PLC.
4. Start the simulation of the process model by clicking onto Start
under Execute.
The EzOPC program is called up automatically when simulation
starts. You will see EzOPC displayed in the Start bar.
If EzOPC is not shown in the Start bar, you need to install it now from
the COSIMIR® PLC CD-ROM.
5. Important control functions of COSIMIR® PLC
116 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
When EzOPC is started, both communication users - EasyPort and the
simulation of the process model – must already be active. Only then can
the communication link be correctly set up.
5. Click onto the EzOPC button in the Start bar to open the EzOPC
window, where you configure the communication between
COSIMIR® PLC and EasyPort.
Note
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 117
6. Carry out the settings for the serial interface. To do so, click onto
Serial Interface in the Configuration menu.
7. Under COM Port , enter the serial interface of your PC, to which
EasyPort is connected and confirm this setting with OK.
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118 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
8. Under Configuration, click onto Communication Setup.
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9. This opens the Communication Setup window.
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120 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
10. Carry out the necessary settings.
Select the entry EasyPort in the section VirtualPLC for Connect
VirtualPLC to: and confirm this with OK.
11. Minimise the EzOPC window.
12. Download the PLC program to the PLC.
13. Start up the PLC.
14. Start the process model simulation.
15. Operate the process model according to how you have planed and
programmed it in the PLC program.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 121
Use the Fault Setting window to set specific faults in the functional
sequence of a process model. Use the internal PLC and the sample PLC
program provided to control the process model. This ensures that a
potential fault behaviour is caused solely by process components. The
PLC program is operating error-free.
The setting of faults is permissible by authorised users only. This is why
the dialog for fault setting is password protected. The default for the
password is didactic. The password can be changed at any time.
Each process model contains a list of possible faults.
5.10
Setting faults in a
process model
5. Important control functions of COSIMIR® PLC
122 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
The following data is required if you want to generate a fault for one of
the listed process components
• Type of fault
• Start of fault
• Duration of fault
With some components, different faults can occur and you can select
these faults from a list of options.
The following mean:
• Reed switch displaced: Reed Switch is mechanically displaced.
• Reed switch jammed: A 1-signal is continually applied at the reed
switch.
• Cable break: A 0–signal is continually applied at a component.
• Short circuit - voltage: A 1-signal is continually applied at
component.
• Malfunction: Complete failure of component.
• Tubing defective: Pneumatic tubing is defective, operating pressure
not achieved.
• Compressed air supply malfunction: Pressure failure.
• Power supply malfunction: Voltage not available.
The time stated for the start of malfunction refers to the simulation time
after the fault is set.
The duration of the fault is to be indicated in seconds.
Error statuses influence the simulation of the process model as soon as
the Fault Simulation is active.
The fault function remains active even if COSIMIR® PLC is terminated or
restarted. It remains active until it is deactivated in the Fault Setting
window.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 123
This is how you set faults in the process model
1. Make sure that a process model is loaded. The process model is to
be controlled via the internal PLC.
2. Open the Fault Setting window by activating Fault Setting in the
Execute menu.
You can also open the Fault Setting via Window Workspaces Teacher
mode. Under Teacher mode are frequently-needed window
combinations for the Fault operation.
Note
5. Important control functions of COSIMIR® PLC
124 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
3. A dialog box is displayed for the password to be entered.
Enter the password. Provided that you have not changed the
password since COSIMIR® PLC has been installed, then the standard
specified password is still valid.
Enter didactic in the Password box.
Note that the password is case-sensitive.
Confirm your entry with OK.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 125
4. The Fault Setting window is now displayed.
5. Important control functions of COSIMIR® PLC
126 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
5. Set a fault function – for example for the PLC input 1B1.
Double click onto the appropriate field in the Type column to display
a list of options. Open the list and select the type of fault, e.g. Cable
break.
The fault is to become active with the start of simulation and to
remain so until the fault is cancelled in Fault Setting. No entry is
therefore required in the Begin column field.
The duration of the fault is arbitrary and likewise, no entry is
therefore required in the Duration column.
Entries in the Begin and Duration column are activated by means of
a double click.
5. Important control functions of COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 127
6. The selected faults are displayed in the Status column.
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128 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
7. Now activate the Fault Simulation mode by selecting Fault
Simulation in the Execute menu.
8. Close the process model in order to deactivate the teacher mode.
This is how you start the simulation of the process model with the set
faults
1. Open the process model with the set fault.
2. Make sure that Fault Simulation is activated.
3. Start the process model simulation.
5. Important control functions of COSIMIR® PLC
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Use the Fault Localisation window to eliminate error functions in the
process model. The set error functions only occur if the process model is
controlled via a PLC program and if the Fault Simulation mode is active.
Distribution process model: The process activity stops once a workpiece
is ejected. The next step, moving the swivel arm into the magazine
position, is not executed.
When monitoring and analysing the process model simulation, you
realise that voltage is applied to the sensor 1B1, but not to the
respective PLC input. You therefore conclude that there is a cable break
at the PLC input 1B1.
5.11
Eliminating faults in a
process model
Example
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130 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
This is how you eliminate a fault in the process model
1. Make sure that the process model is loaded.
2. Open the Fault Localisation window by clicking onto the Fault
Localisation window in the Execute menu.
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3. The Fault Localisation window is displayed.
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132 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
4. In the line 1B1 PLC input, double click onto No fault and select Cable
break in the list.
The button is now illuminated in yellow.
If the fault Is correctly identified, the next process model simulation
will be executed fault-free.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 133
5. In teacher mode, the Fault Localisation window looks as follows:
• If you have correctly identified and entered the fault, the process
model is executed correctly in the next simulation cycle.
• If you have failed to correctly identify the cause of the fault, then the
fault remains in place.
• If you have erroneously identified the cause of the fault as a
mechanically displaced sensor, then you have created an additional
fault within the process as a result of this and the fault is active from
the next simulation onwards.
Note
5. Important control functions of COSIMIR® PLC
134 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Each action in the Fault Localisation window is logged in a log file.
Authorised persons are able view the log file.
The log file contains a list of activities which have been listed in the
Fault Localisation window. The entries contain the following data
entered by the student.
• Date
• Time
Faults, which have been correctly identified and eliminated are marked
in green.
5.12
Logging of eliminated
faults
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 135
This is how you access the log file
1. Open the Fault Log window by activiating Fault Log in the Execute
menu.
2. A dialog box is then displayed for you to enter the password.
Enter the password. Provided that you have not changed the
password since COSIMIR® PLC has been installed, the the standard
specified password is still valid.
Enter didactic in the Password box.
Please note that the password is case-sensitive.
Confirm your entry with OK.
3. The Fault Log window is now displayed.
To cancel the fault log, activate the context-sensitive menu via the right
mouse button and select the appropriate command.
Notes
136 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
COSIMIR® PLC is a multimedia training aid for use in the field of
automated systems. The examples given represent practice-related
applications. The exercises are based on industrial process sequences
and aim to portray a holistic training process. With COSIMIR® PLC , you
will be training in both methodology and professional competency.
COSIMIR® PLC provides process models for systems of varying
complexity from the production sector.
The general training aims to be achieved with COSIMIR® PLC are to be
able to
• Analyse and understand the mode of operation and system
structure of PLC controlled systems,
• Create and test PLC programs or clearly configured systems and
• Carry out systematic fault finding as part of maintenance and
corrective maintenance.
These general training aims cover all subject areas that can be taught by
means of simulated processes. The main focus of training is on a
methodical approach.
Significance of the training contents in industrial practice
One of the most important influences in industrial development over the
past few years has been the ever increasing degree of automation,
growing complexity of processes and faster operating cycles. The
keywords here are optimal utilisation of high investment, flexible and
cost effective production. More specifically these include:
• High degree of machine efficiency,
• Less downtimes,
• Optimisation of systems,
• Continual improvement processes.
6. The following training contents can be taught with
COSIMIR® PLC
6.1
Training contents
6. The following training contents can be taught with COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 137
As a result of this, those who are dealing directly with a system are to
some extent faced with entirely new demands. A system operator now
takes on minor maintenance work and possibly some corrective
maintenance, as does the installer. A mechanical maintenance engineer
must have sufficient knowledge and understanding of electrical and
electronic control technology to draw the necessary conclusions
regarding pneumatics, hydraulics and mechanics. Conversely, an
electrical engineer requires knowledge about pneumatic and hydraulic
actuators. At the same time, these changing requirements lead to new
forms of collaboration.
Grouped together, these requirements can be put into three areas
• Technology know-how
• System know-how and system understanding
• Socio-cultural skills
With COSIMIR® PLC you will develop your knowledge and practice your
skills in the areas of technology know-how as well as system know-how
and understanding. Apart from technical know-how, these skills also
include decision-making responsibility and methodological
compentency .
The target group for COSIMIR® PLC includes all those whose
professional area of activities involves PLC programming, maintenance
and corrective maintenance or those who need to have a basic
knowledge on these topics.
These include:
• Professional teachers/instructors
– Mechatronics engineers
– Electrical engineers, for instance specialising in automation
technology
– Industrial mechanical engineers
• Professional qualifications in metal-working and electrical
engineering
• Vocational training at colleges and universities
6.2
Target group
6. The following training contents can be taught with COSIMIR® PLC
138 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Knowledge is required of the following in order to work and train with
COSIMIR® PLC :
• A basic knowledge of control technology: Structure of an automated
system
• A basic knowledge of PLC technology: Design and mode of operation
of a PLC
• A basic knowledge of PLC programming and handling of a PLC
programming tool, such as the programming system SIMATIC STEP 7
• A basic knowledge of pneumatic control technology: Drives, control
elements
• A basic kowledge of sensor technology: Limit switches, contactless
proximity sensors
• A basic knowledge of designing, wiring and tubing of
electropneumatic systems.
• A basic knowledge of electrical engineering: Electical variables,
correlations and calculations thereof, direct and alternating current,
methods of electrical measurement
• Basic knowledge of how to read and interpret circuit diagrams
• The ability to deal with and operate Windows programs
Below is a list of training aims on the subjects of system know-how, PLC
programming and systematic fault finding. The training aims are taken
from the 1999 sillabus for mechatronics engineers. The contents have
been adapted and weighted accordingly such as for instance for the
2003 syllabi for electronic engineers.
Mechatronics and electronics engineers are two examples of how
vocational training in Germany is currently updated and adapted to the
new training area concept.
The tables below list only those training aims which can also be taught
with COSIMIR® PLC.
6.3
Previous knowledge
6.4
Example: Assiging
training aims to training
courses
6. The following training contents can be taught with COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 139
Training content: Analysis of mode of operation and structure of a
system
Mechatronics engineer
Area of training Training aims
Area of training 1:
Analysis of functional interrelationships
within mechatronic systems
To read and use technical documentation.
To have a command of processes in order to be able to
analyse and document functional interrelationships.
To draw up and interpret block diagrams.
To identify the signal, material and energy flow with the
help of technical documentation.
Area of training 4:
Investigating the energy and information
flow in electrical, pneumatic and
hydraulic modules
To understand basic control technology circuits: To actuate
(pneumatically and hydraulically) a single-acting and
double-acting cylinder, basic logic operations, contactor
circuits, digital circuits.
To read and use circuit diagrams.
To identify power supply units in electrotechnology,
pneumatics and hydraulics.
To identify and describe the control functions of simple
control systems.
To design a control system (block diagram).
To identify signals & measured values in control systems.
Area of training 7:
Realisation of mechatronic subsystems
To understand and describe mechatronic subsystem
structures.
To understand and analyse the mode of operation, signal
behaviour and the use of components (sensors and
actuators).
To understand basic circuits and the mode of operation of
drives.
6. The following training contents can be taught with COSIMIR® PLC
140 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Mechatronics engineers (continuation)
Area of training Training aims
Area of training 8:
Design and construction of mechatronic
systems
To describe the structure and signal pattern of mechatronic
systems.
To analyse the effect of changing operating conditions on a
process cycle.
Area of training 9:
Analysing the information flow in
complex mechatronic systems
To describe the information structure (signal structure,
signal generation, signal transmission) of a system with the
help of circuit diagrams.
To establish the interrelationship between electrical,
pneumatic and hydraulic components.
To analyse signals (binary, analogue, digital) and to
deduce potential error sources.
To use computer-aided diagnostic methods, e.g. testing
and diagnostic functions of a programming system or bus
system.
Area of training 11:
Commissioning, fault finding and
corrective procedures
To analyse mechatronic systems on the basis of technical
documentation and to break down their configuration into
function blocks.
Area of training 13:
Handover of mechatronic systems to
customers
To describe mechatronic systems.
To create operating instructions and documentation.
6. The following training contents can be taught with COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 141
Training content: PLC programming and testing of the program
Mechatronics engineers
Area of training Training aim
Area of training 7:
Realisation of mechatronic subsystems
To understand the design and mode of operation of a PLC.
To design and document control systems for simple
applications.
To program simple control processes via PLC: Logic
operations, memory functions, timers, counters.
To carry out programming in one of the PLC programming
languages – ladder diagram, function chart or statement
list – in accordance with DIN EN 61131-3.
To document control systems in function diagrams and
function chart according to DIN EN 60848.
Area of training 8:
Design and creation of mechatronic
systems
To program mechatronic systems in one of the
programming languages – ladder diagram, function chart,
statement list, sequential function chart.
To program the mode section.
To program a sequence control.
Area of training 9:
Analysing the information flow in
complex mechatronic systems
To use computer-aided diagnostic methods, e.g. testing
and diagnostic functions of the programming system.
Area of training 11:
Commissioning, fault finding and
corrective procedures
To eliminate errors in the PLC program.
6. The following training contents can be taught with COSIMIR® PLC
142 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Training content: Systematic fault finding on systems
Mechatronics engineers
Area of training Training aim
Area of training 4:
Analysing the energy and information
flow in electrical and hydraulic modules
Fault finding on simple modules with the help of
measurement technology.
Area of training 7:
Realisation of mechatronic subsystems
To check control systems for simple applications, e.g. by
means of signal analysis.
Area of training 8:
Design and creation of mechatronic
systems
To identify errors by means of signal analyses at interfaces
and eleminating error causes.
Computer simulation
Area of training 9:
Analysing the information flow within
complex mechatronic systems
To analyse signals (binary, analogue, digital) and deduce
potential error sources.
To use computer-aided diagnostic methods, e.g. the
testing and diagnostic function of the programming
system.
Area of training 11:
Commissioning, fault finding and
corrective procedures
To understand the procedure for fault finding in electrical,
pneumatic and hydraulic systems.
To carry out a fault analysis.
To have a command of and apply systematic fault finding.
To recognise typical error causes.
To make specific use of diagnostic systems.
To document faults.
To create a log of corrective procedures.
6. The following training contents can be taught with COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 143
COSIMIR® PLC is a motivating, multimedia training aid on the subject of
automated systems.
The systems vary in complexity and can be flexibly programmed.
Problem definitions can thus be formulated according to requirements
and the instructor’s previous knowledge. It is therefore for instance
possible to analyse the mode of operation of individual components.
Similarly, it is possible to program and test the mode section of a
system.
Simulated processes have an innate didactic quality:
• They are practice-related and as representational as possible.
• The ability to experiment with process models creates an
environment close to that of an actual system, which is the real
object of training and knowledge is tested and consolidated.
• Practice-related experience with simulated processes lends a new
dimension and quality to knowledge in that theoretical knowledge
becomes application and practice-orientated competence.
COSIMIR® PLC supports self-motivated, experimental learning:
• A simulated system operates in the same way as an actual system.
This enables students, for instance, to immediately see whether
they have programmed the sequence of a system correctly. The
effect of incorrect operation also is apparent without causing any
damage to the system. This enables students to independently
reach and analyse their findings.
• Students can access technical documentation about process models
according to their needs.
• Students can practice their knowledge and skills on a wide range of
different process models.
6.5
The training concept of
COSIMIR® PLC
6. The following training contents can be taught with COSIMIR® PLC
144 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
What are the advantages of COSIMIR® PLC as a training medium?
• COSIMIR® PLC is a PC-assisted training aid and therefore represents
an alternative training method. Training can be devised in a
diversified and motivating way.
• Industry-based process models are used to practice and consolidate
the knowledge and skills acquired on actual systems.
• Simulated processes can be used to highlight and experiment with
statuses, which would be too hazardous on actual systems.
• Efficient, practice-related hands-on training is possible without the
use of an actual system.
• A one-off, actual system is available in the form of several simulated
systems, which increases the availability of this system for training
purposes.
• The actual and virtual world of automation can be combined in any
way and adapted to the requirements of the learning process.
• All systems simulated in COSIMIR® PLC are also available in the form
of actual systems and can be ideally combined and supplemented
for training.
• Skills and activities which can only be acquired and practiced on
actual systems should not to be replaced, but supplemented,
practised and consolidated.
• Simulation is an advanced tool for use with automated systems.
Example 1
To ensure that the PLC programs and design of a system are ready at
the same time, appropriate simulation of the system is used to test
the PLC program.
Example 2:
Since production systems should have as few downtimes as
possible, simulated systems are often used to train and familiarise
operators and maintenance personnel with systems.
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 145
COSIMIR® PLC supports you in many different ways with the
familiarisation and analysis of a system.
The systematic procedure you use to do so and the knowledge you
acquire can be transferred to any system and of course also an actual
system.
Load a process model to COSIMIR® PLC . Whilst the process model is
being simulated, you can control, monitor and analyse the process,
which follows the specification of the PLC program provided. The
supplied PLC program defines a possible sequence and operation of the
process. The process model can however also be controlled via a
different PLC program.
• The selected process model is operational and there are no faults in
the process.
• The selected process model is to be controlled via the internal PLC.
A correct STEP 7 PLC program is available in the form of a sample
program. The sample program is loaded to the internal PLC.
These training aims can be taught with the use of COSIMIR® PLC :
• To analyse and understand automated systems on the basis of
technical documentation and with the help of simulated processes.
• To identify the function and mode of operation of the individual
components.
• To break down the system into function blocks in order to identify
the system structure.
• To identify and track the signal , material and energy flow of the
system.
7. This is how you establish the mode of operation and
structure of a system in COSIMIR® PLC
Prerequisite
7.1
Training aims
Main training aim
General training aims
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
146 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
• To identify the controller behaviour and the operating sequence of
the system with the help of the technical documentation, i.e.
Function Chart.
• To familiarise students with the operation of the system.
• To understand the product and the processing method.
• To investigate the system with the help of the simulated process.
• To use the technical documentation specifically to investigate the
system.
The technical documentation is comprised of the following: Function
chart, circuit diagrams, operating instructions, commissioning
instructions, data sheets.
• To identify the advantages of a simulated process for the operating
sequence.
To be able to understand and analyse a system, you will need to
subdivide.
One possible way, is to subdivide a system into the areas of system and
controller structure, mechanical configuration, drive technology, control
elements, control system, signal generators and energy supply.
No. Function scope Components and component parts
1 System structure and
controller structure
Program flow charts, function charts, function diagrams,
description
2 Mechanical configuration Support and mounting unit, function units, adjustment
3 Drive technology Electrics, hydraulics, pneumatics, mechanics
4 Control elements Electrics, hydraulics, pneumatics, mechanics
5 Control system Electrical relay controller, PLC, pneumatics, CNC, robot controllers
6 Signal generators Binary sensors, analogue sensors, digital sensors
7 Energy supply Electrics, hydraulics, pneumatics
Structure of a system
7.2
Methods
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
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This structure serves as the basis for a systematic procedure to analyse
and investigate the system.
Questions regarding the individual function scopes provide ideas and
guidance as to what exactly you should investigate within the individual
function scopes.
Function scope - system and controller structure
– What is the function of the system?
– What is the system to produce?
– How is the operating sequence of the system defined?
– What control functions are provided?
– What display functions are provided?
– What type of control system is available: Logic control system,
sequence control?
– What function units does the system consist of?
– Are the function units or components networked?
– What bus systems are used: PROFIBUS, AS-i, Ethernet, or similar?
– What information is exchanged within the system?
– What information is exchanged with other systems or higher order
processes?
– What does the material flow look like?
– What does the signal flow look like?·
– What does the energy flow look like?
– What does the information flow look like?
– What are the possibilities of tracing the signal flow?
– Program flow chart
– Function chart
– Function diagrams
– Description
– Operating instructions
– Commissioning instructions
Questions
Documents
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148 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Function scope - drive technology
– What drives are incorporated: Linear drive, swivel drive, rotary drive,
electric motor
– Which drive technology is used: Electrical, pneumatic, hydraulic?
– Circuit diagrams
– Data sheets
Function scope - control elements
– What control elements are incorporated?
– How are the control elements actuated: Electrically, pneumatically,
hydraulically?
– How high is the control voltage used for electrically actuated control
elements?
– What interfaces occur between the signal control section and the
power section?
– How do the control elements react in the event of Emergency-Stop?
– What are the status display options of control elements?
– Circuit diagrams·
– Data sheets
Function scope - the control sysem
– How is the control system realised: PLC, relay control, robot control,
CNC, pneumatic control?
– Which control energy does the PLC require?
– What is the voltage applied at the PLC inputs?
– What is the voltage applied to the PLC outputs?
– Is a bus system used?
– Which fieldbus system forms part of the control system?
– Circuit diagrams
– Data sheets
Questions
Documents
Questions
Documents
Questions
Documents
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Function scope - signal generators
– Which signal generators are incorporated: Binary, analogue, digital?
– Which electronic signal generators are incorporated: Optical
sensors, inductive sensors, capacitive sensors, magnetic sensors?
– What is the design (polarity of the output signal) of the electronic
sensors: PNP, NPN?
– Which mechanically actuated sensors are incorporated?
– Which pressure sensors are incorporated?
– What are the status display options of the sensors?
– Circuit diagrams
– Data sheets
Function scope - energy supply
– Which energy supply is used?
– How high is the operating pressure in the case of pneumatic or
hydraulic energy supply?
– Is direct or alternating current used?
– How high is the operating voltage: 24 V or 230 V?
– Circuit diagrams
– Data sheets
Questions
Documents
Questions
Documents
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150 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
COSIMIR® PLC supports you with the following during your analysis and
investigation of the system:
• Simulation of the process model and execution of the PLC program
in the internal PLC.
• Window for PLC inputs/outputs: Display of the PLC inputs/outputs.
• Window for manual operation: To monitor process activities and
process statuses.
• Window for manual operation: To set breakpoints to enable you to
monitor system operation step by step.
• Window for manual operation: To set specific breakpoints in order to
stop the process at a particular step.
• COSIMIR® PLC Assistant: Provides information on-line, such as
circuit diagrams for the process model.
Investigating the operating sequence of the Distribution station
Investigate the operating sequence of the distribution station. To do so,
use the checklist containing the system structure.
Answer the following questions:
• How is the initial position of the system defined?
• What is the purpose of the Reset function?
• What is defined as the start precondition: Does it include the
execution of the Reset function?
• How does the distribution station react if no more workpieces are
available?
• No more workpieces are available in the stacking magazine. What
do you need to do for the station to operate correctly again?
7.3
Support via
COSIMIR® PLC
7.4
Example
Exercise
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 151
1. Load the Distribution process model controlled via the internal PLC.
2. The system can be broken down into the following function blocks:
Stacking magazine, swivel drive and electrical. The electrics also
include the PLC.
Implementation
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
152 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
3. Refer to the technical documentation for information regarding the
initial position and start condition of the system.
To do so, access the on-line help for the process model. Click onto
Help with the Work Cell in the Help menu.
The required information is available in the chapters „The
Distribution Station“ and „Technical Documentation“.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 153
Initial position: Ejecting cylinder extended (1B2=1) and swivel arm at
magazine (3S1=1) and workpiece not picked up (2B1=0).
The system moves to the initial position via the Reset function.
The start condition is met if the station is reset and in the initial
position.
4. Start the simulation of the process model by clicking onto Start in
the Execute menu.
5. Control the process by means of the pushbuttons and switches of
the control console.
Carry out the reset function first by clicking onto the green
illuminated Reset button.
Then place two workpieces into the magazine by clicking onto the
workpieces on the slotted assembly board.
Start executing the process by clicking onto the Start button.
You can now follow the implementation of the process.
Result
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
154 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
6. If there are no further workpieces in the magazine, the swivel arm
stops in the adjacent station position. The indicator light Q1 is
illuminated. The designation of the indicator light in the circuit
diagram is H3.
7. Fill the magazine with workpieces. Click onto the illuminated Start
button to acknowledge that you have finished filling the magazine.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 155
8. Open the Manual Operation window, if you want to execute a
process sequence step by step, to enable you to monitor it more
effectively. To do so, click onto Manual Operation in the Execute
menu.
Highlight all the process activities and set breakpoints at these
process activities by activating the context sensitive menu via the
right mouse button. Select Stop at Value Change.
Start the simulation of the process model. Simulation stops at each
value change. As soon as simulation is re-started, the next step is
executed.
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
156 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
9. You can trace the signals in the process via the status display in the
Manual Operation window or via the LEDs of the process
components.
10. To access information regarding the circuit diagram designations of
process components, click onto the LED or the air connection of a
component.
If, as a result of simulation, the process model reaches a status you
cannot or do not want to work with any longer, return the process model
to the initial position by stopping the simulation. Then click onto Work
Cell Initial Position in the Processing menu.
Determining the components of the Distribution station
Investigate the design of the Distribution station. Use the checklist
detailing the structure of the station and the questions regarding the
system for this.
Answer the following questions:
• With which valve is the swivel drive actuated?
• How is the vacuum generated?
• What are the designations of the solenoid coils of the valve for the
ejection of the workpieces?
• Via which sensor is the filling level of the magazine monitored?
• How many PLC inputs and PLC outputs are required for the control of
the Distribution station?
Note
7.5
Example
Exercise
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 157
1. Load the Distribution process model controlled via the internal PLC.
Implementation
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
158 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
2. Refer to the technical documentation for information regarding the
process components and their circuit diagram designations.
To do so, open the on-line help for the process model and click onto
Help with the Work Cell in the Help menu.
The required information is available in the chapter „Technical
Documentation“.
The swivel drive is actuated via two 3/2-way solenoid valves. This valve
combination has the function of a 5/3-way solenoid valve with mid-
position pressurised. The circuit diagram designation for this valve is
3V1.
The vacuum is generated via a 2/2-way solenoid valve. The second
2/2-way solenoid valve creates an ejector pulse, which results in
reliable ejection once the vacuum is switched off. The circuit diagram
designation for the valve is 2V1.
All valves are housed on one valve terminal.
The designation of the valve coil of valve 1V1 for the actuation of the
ejecting cylinder is 1Y1.
The filling level of the magazine is checked via the optical sensor with
the circuit diagram designation B4.
Result
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 159
3. Take a look also at the process components in the process model
itself.
Click onto the LED or the air connection in order to display the
designation.
To enlarge or turn the components, use the options in the View
menu.
You can restore the standard setting of the process model by
clicking onto Standard in the View menu and then selecting
Presetting.
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160 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
4. Determine the number of PLC inputs and outputs required to control
the process.
You will find the relevant information for this in the technical
documentation via the on-line help.
You can however also display the PLC inputs/outputs and their
statuses in a separate window for the process model by clicking
onto Inputs/Outputs under Extras and selecting Display Inputs and
Display Outputs.
The process control system requires 12 PLC inputs and 8 PLC outputs.
Result
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 161
Tracing the signal and energy flow on the Distribution process model
Investigate the signal and energy flow of the Distribution station.
To do so, trace the signal of the sensor 1B1 up to the respective PLC
input.
Trace the signal and energy flow from the PLC output 3Y1 to the
pneumatic drive.
Answer the following additional questions:
• To which PLC input is the sensor 2S2 connected?
• To which PLC input is the sensor B4 connected?
• Which drive is actuated via the solenoid coil 1Y1?
• To which PLC output is the vacuum generator connected?
1. Load the Distribution process model controlled via the internal PLC.
7.6
Example
Exercise
Implementation
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
162 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
2. Refer to the technical documentation for information regarding the
signal and energy flow of the sensor 1B1 and the PLC output 3Y1.
To do so, open the on-line help for the process model and click onto
Help with the Work Cell in the Help menu.
The required information is available in the chapter „Technical
Documentation“.
The sensor 1B1 is connected to the PLC input 1B1 (I0.2).
The PLC output 3Y1 (O 0.3) controls the valve coil 3Y1 of the valve 3V1.
3. Move the process model into the initial position by clicking onto
Work Cell Initial Position in the Processing menu.
4. Start the simulation by clicking onto Start in the Execute menu.
5. Establish where the components are located in the system and
investigate the signals and energy flow of these. You will recognise
the components by their circuit diagram designation.
6. Control the process by using the pushbuttons and switches of the
control console.
First, carry out the reset function by clicking onto the green
illuminated Reset button.
Then fill the magazine with workpieces by clicking onto one of the
workpieces on the slotted assembly board.
Start the process operation by clicking onto the Start button.
You can now follow the process execution.
Result
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 163
7. Carry out the process activity step-by-step to enable you to better
monitor everything. Open the Manual Operation window by clicking
onto Manual Operation in the Execute menu.
Highlight all the process activities and set the breakpoints at these
by activating the context sensitive menu via the right mouse button.
Select Stop at Value Change.
Start the simulation of the process model. Simulation stops with
each value change. The next step in the process is executed as soon
as you restart simulation.
7. This is how you establish the mode of operation and structure of a system in COSIMIR® PLC
164 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
8. Monitor the signal flow of the sensor 1B1.
The sensor 1B1 is connected to the PLC input 1B1, i.e. to
STATION_1B1. The sensor status can be established via the LED on
the sensor. You can also monitor the switching status of the sensor
in the Manual Operation window.
If the sensor 1B1 switches, then a 1-signal is applied at the PLC
input STATION_1B1. The status of the PLC inputs is displayed in the
Inputs window. Open this window by clicking onto PLC
Inputs/Outputs in the Extras menu and select Display Inputs.
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© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 165
9. Monitor the signal and energy flow of the PLC output STATION_3Y1.
The PLC output STATION_3Y1 is connected to the valve coil 3Y1. The
status of the PLC can be established in the Ouputs window. Open
this window by clicking onto PLC Inputs/Outputs in the Extras menu
and select Display Outputs.
If a 1-signal is applied at the PLC input, voltage is also applied at the
valve coil 3Y1. The LED of the valve coil is illuminated. If a 0-signal is
also applied simultaneously at the valve coil 3Y2, then the
valve 3V1 switches. The swivel arm moves into the magazine
position.
166 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
When investigating a system, the main focus can be put on
familiarisation with the components, in which case the system will not
be not controlled via a PLC program.
To enable you to more closely observe the mode of operation and
behaviour of a component, COSIMIR® PLC allows you to operate
individual actuators “by hand”, similar to an actual station. With manual
operation, an electrical signal is generated at the selected solenoid coil
and the valve switches according to the signal applied and controls the
drive.
The system components can be specifically controlled via manual
operation. You can trace the signal and energy flow, identify interfaces
and therefore systematically analyse and understand the system.
• The process model selected is operational and there are no faults
within the process.
• The process model selected will not be controlled via a PLC. The
working energies current and compressed air are connected.
The following training aims can be taught with the use of COSIMIR® PLC:
• Familiarisation with the individual components of an automated
system: Mode of operation, status display elements, mechanical
characteristics.
8. This is how you establish the mode of operation of the
components forming part of a system in COSIMIR® PLC
Prerequisite
8.1
Training aims
Main training aim
8. This is how you establish the mode of operation of the components forming part of a system in
COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 167
• Familiarisation with the mode of operation of sensors and limit
switches.
• To be able to identify application areas for optical, magnetic,
inductive and capacitive sensors.
• To be familiar with the DC motor as an example of an electrical drive.
• To know of examples for pneumatic linear drives and rotary drives.
• To be familiar with the design and mode of operation of
electropneumatic valves.
• To analyse and understand the signal and energy flow of
components.
• To be familiar with electropneumatic circuits.
• To be familiar with status display components on electrical
components and to use these for signal tracing.
Use a systematic approach to familiarise yourself with a system or
system components. The instructions for a systematic procedure are set
out in Chapter 7.
COSIMIR® PLC supports you with the following during your analysis and
investigation of the components which formpart of a system:
• Simulation of the process model. The PLC programs are not active
during this.
• Window for manual operation: Monitoring of process activities and
statuses.
• Window for manual operation: Initiating individual process
activities.
• COSIMIR® PLC Assistant: Provides information on-line, such as
circuit diagrams for the process model.
General training aims
8.2
Methods
8.3
Support via
COSIMIR® PLC
8. This is how you establish the mode of operation of the components forming part of a system in
COSIMIR® PLC
168 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Investigating the mode of operation of the ejecting cylinder in the
stacking magazine module
Investigate the mode of operation of the stacking magazine.
Answer the following questions:
• How is the initial position of the stacking magazine defined?
• What is the status of the ejecting cylinder in the initial position?
• How do you identify whether the ejecting cylinder is extended or
retracted?
• Via which valve is the ejecting cylinder actuated?
• What is the designation of the valve solenoid coil for the actuation of
the ejecting cylinder?
• How can you identify whether voltage is applied at the solenoid coil?
• Is the sensor for workpiece detection an inductive, capacitive or
optical sensor?
• Which signal is applied at the sensor if a workpiece is available in
the magazine?
8.4
Example
Exercise
8. This is how you establish the mode of operation of the components forming part of a system in
COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 169
1. Load the stacking magazine process model. Since neither a sample
PLC program is available for the stacking magazine nor a PLC
program is to be executed, you can load the work cell for the internal
or external PLC.
Proceed as follows, when carrying the investigation of individual
components on a process model for which a sample program is
available:
• Load the process model controlled via the internal PLC.
• Open the Manual Operation window.
• Activate the context-sensitive menu via the right mouse button.
Select Disconnect Controllers.
• Carry out your investigations by means of manual operation.
• Once you have completed your investigations and want to control
the process model via the internal PLC, connect the simulation of the
process model with the internal PLC. To do so, activate the context-
sensitive menu via the right mouse button and select Restore I/O
Connections.
Implementation
Note
8. This is how you establish the mode of operation of the components forming part of a system in
COSIMIR® PLC
170 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
2. Establish which components the stacking magazine consists of.
You can find the relevant information by clicking onto the LED or the
compressed air connection of the component. Additional
information is available in the technical documentation. This
technical documentation is available on-line. To access this, open
the on-line help for the process model by clicking onto Help with the
Work Cell in the Help menu.
You will find the required information in the chapter „Technical
Documentation“.
8. This is how you establish the mode of operation of the components forming part of a system in
COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 171
The ejecting cylinder separates out the workpieces.
The end positions of the ejecting cylinder are detected via two sensors:
Sensor 1B1 (ejecting cylinder retracted), sensor 1B2 (ejecting cylinder
extended).
The valve for the actuation of the ejecting cylinder is a 5/2-way solenoid
valve with the designation 1V1.
The valve coil 1Y1 actuates the valve 1V1.
The optical sensor B4 detects whether a workpiece is available in the
magazine.
3. Make sure that the stacking magazine is in the initial position by
clicking onto Work Cell Initial Position in the Processing menu.
In the initial position, the ejecting cylinder is extended.
4. Start the process model simulation by clicking onto Start in the
Execute menu.
Result
8. This is how you establish the mode of operation of the components forming part of a system in
COSIMIR® PLC
172 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
5. Open the Manual Operation window by clicking onto Manual
Operation in the Execute menu.
6. Add a workpiece into the magazine by clicking onto one of the
workpieces on the slotted assembly board.
Check whether the status of the sensor B4 changes.
You can identify the switching status of the sensor on the LED of the
sensor. You can however also establish the sensor status via the
Manual Operation window.
No workpiece available: B4=1
Workpiece available: B4=0.
Result
8. This is how you establish the mode of operation of the components forming part of a system in
COSIMIR® PLC
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 173
7. Eject a workpiece from the magazine by applying a 1-signal at valve
coil 1Y1.
Double click onto line 1 of the process activities. Valve coil 1Y1 is set
at value 1 and the ejecting cylinder ejects a workpiece. No
compressed air tubing is shown in the simulation. Applied
compressed air is signalled by means of a blue connection.
8. This is how you establish the mode of operation of the components forming part of a system in
COSIMIR® PLC
174 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
8. Return the magazine ejector to the magazine by double clicking onto
line1 of the process activities. This double click changes the value of
the valve coil from 1 to 0; the ejecting cylinder extends again.
9. Remove the ejected workpiece by double clicking onto line 2 of the
process activities. The workpiece is removed.
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 175
COSIMIR® PLC offers you numerous process models for automated
applications that are typical in industry. You determine the process
sequence, which can be either simple or complex. You then create the
PLC program for this sequence in the programming system and for the
PLC of your choice. The PLC program is subsequently used to control the
process model. You can immediately detect whether the PLC program is
operating correctly. If errors occur, then use the testing and diagnostic
functions of your programming system for error detection and error
elimination.
The main focus of COSIMIR® PLC as part of PLC programming is on:
• Practising a systematic procedure to create the PLC program.
• Systematic testing of the PLC program on the simulated process.
The advantage is that relevant actual systems exist for these process
models. This enables you to carry out comprehensive commissioning on
the actual systems with the tested PLC programs.
• The selected process model is operational and there are no faults
within the process.
• The process model selected is to be controlled via an external PLC.
COSIMIR® PLC is a tool for the process of creating a PLC program. With
the help of this tool you can teach the following training contents.
• To design, create and test PLC programs for simple motion
sequences.
9. This is how you use COSIMIR® PLC in PLC programming
Prerequisite
9.1
Training aims
Main training aim for the
Beginners target group
Beginners
9. This is how you use COSIMIR® PLC in PLC programming
176 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
• To describe the design and function of a PLC.
• To list the differences between a PLC and relay control.
• To realise simple control tasks using basic logic functions (and
timers).
• To program simple control tasks in one of the programming
languages: Ladder diagram, function chart or statement list
according to DIN EN 61131-3.
• To test PLC programs for simple control tasks.
• To systematically solve simple control problems from problem
definition and analysis through to finding a solution, programming,
checking and documentation.
• To design, create and test a PLC program for extensive control
systems.
• To program sequence control systems in sequential function chart
according to DIN EN 61131-3.
• To program the mode section.
• To utilise the diagnostic and testing functions of the PLC
programming system.
• To systematically solve control tasks from problem definition and
analaysis through to finding a solution, programming, checking and
documentation.
PLC programs – or more generally control programs - are an important
component part of an automated system. In order for PLC programs to
be as error-free, easy to maintain and cost effective as possible, they
need to be systematically designed, well structured and documented in
detail.
General training aims for
the target group Beginners
Main training aim for the
Advanced target group
General training aim for
the Advanced target group
9.2
Methods
9. This is how you use COSIMIR® PLC in PLC programming
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 177
Proceeding in stages has proved a successful method for the
development of a PLC program. Breaking down the process into stages
or sections provides a targeted, systematic approach and gives clearly
configured results that can be checked against the problem definition.
Stages Activities Result/documents
Specification
(description of the
control task)
– Description of the system
– Defining the system process
– Function description
– Positional sketch
– Technology layout
Planning and design
(description of the
solution)
– Planning the system
– Defining the control technology
requirements (Emergency-Stop,
modes of operation,
visualisation...)
– Design of the PLC program
(formal representation of the
sequence and logic of the PLC
program)
– Circuit diagrams·
– Parts lists·
– Solution in the form of a function
table or logic diagram to
IEC 617-12 for sequence
controllers
– Solution in the form of a function
chart to DIN EN 60848 for
sequence controllers
– Function diagrams
– Definition of software modules
Realisation
(Implementation of the
solution)
– Programming of the PLC progam
– Simulation and testing of program
sections and the overall program
– Construction of the system
– Annotated PLC program in one
of the programming languages
to DIN EN 61131-3
Commissioning
(integration and
testing of the solution)
– Testing and commissioning of the
control system
– Operational PLC program
– Commissioning report
– Storage medium with PLC program
– Full documentation
Stages within the systematic solution of a control task
9. This is how you use COSIMIR® PLC in PLC programming
178 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
COSIMIR® PLC with the following for PLC programming:
• Industry-typical, realistic process models of varying complexity.
• Simulation of the process model.
• Control of the process model via OPC interface using any PLC (for
example via S7-PLCSIM).
• Window for PLC inputs/outputs: Display of PLC inputs/outputs.
• Window for manual operation: Monitoring process activities and
process statuses.
• COSIMIR® PLC Assistant: Provides information such as system
description or circuit diagrams.
Programming the display of the initial position of the Distribution
process model.
On the Distribution station, the indicator light H1 is to be illuminated if
the station is in the initial position.
The technical documentation for the station is to be used, such as the
circuit diagrams and symbols table. You will find these in COSIMIR® PLC
Assistant.
• Represent the control function in the form of a logic diagram.
• Program the control task in one of the following languages: Ladder
diagram, function chart or statement list.
• Test the PLC program using the simulated process model.
9.3
Support via
COSIMIR® PLC
9.4
Example
Exercise
Ancillary conditions
Your task
9. This is how you use COSIMIR® PLC in PLC programming
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 179
Implementation using the programming system STEP 7and the Soft PLC
S7-PLCSIM
1. Start COSIMIR® PLC .
2. Load the Distribution process model controlled via the external PLC.
3. Use the technical documentation to find out how the initial position
of the station is defined.
To do so, open the on-line help for the process model and click onto
Help with the Work Cell in the Help menu.
You will find the required information in the chapters „The
Distribution Station“ and „Technical Documentation“.
9. This is how you use COSIMIR® PLC in PLC programming
180 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Initial position: Ejecting cylinder extended (1B2=1) and swivel arm at
magazine (3S1=1) workpiece not picked up (2B1=0).
4. Formulate the control function in the form of a logic diagram.
1B1 H1
3S1
2B1
&
Logic diagram
5. Create the symbols table for the control function.
Take the required inputs/outputs from the general symbols table for
the Distribution station. The symbols table is available via the on-
line Help for the work cell. Activate the on-line Help by clicking onto
Help with the Work Cell in the Help menu
Symbol Address Data
type
Comment
1B2 I 0.1 BOOL Ejecting cylinder extended
2B1 I 0.3 BOOL Workpiece picked up
3S1 I 0.4 BOOL Swivel arm in magazine
position
H1 O 1.0 BOOL Indicator light
Initial position
6. Start STEP 7 or the SIMATIC Manager.
7. Plan a project for the control function.
Result
Result
Result
9. This is how you use COSIMIR® PLC in PLC programming
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 181
8. Create the PLC program and store this.
9. Open S7-PLCSIM by clicking onto Simulate Module under Options in
the SIMATIC Manager.
10. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto
the MRES button in the CPU 300/400 window.
9. This is how you use COSIMIR® PLC in PLC programming
182 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
11. Load the PLC program to the S7-PLCSIM. In order to do this,
highlight the folder Module, then click onto Load in the Target
System menu.
12. Start the S7-PLCSIM by clicking onto the box next to RUN in the CPU
300/400 window.
13. Start the process model simulation by activating Start in the
Execute menu.
With the starting of the process model simulation, the communication
program EzOPC is also started. If EzOPC is started, both communication
users - S7-PLCSIM and process model simulation must already be
active. Only then can the communication link be correctly set up.
Note
9. This is how you use COSIMIR® PLC in PLC programming
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 183
14. Carry out the settings in EzOPC.
Click onto the EzOPC button in the Start bar. This will open the
EzOPC window.
Click onto Communication Setup in the Configuration menu.
Carry out the necessary settings.
In the Easy Port section, select Not Connected for EasyPort 1.
In the PLCSIM section, select Installed for STEP 7 PLCSIM V5.x.
Accept the preset values 0 and 32 for Start Byte and End Byte
without changing it, although only the first four bytes are required.
In the section VirtualPLC, select PLCSIM for Connect VirtualPLC to:.
Click onto OK to confirm your settings.
9. This is how you use COSIMIR® PLC in PLC programming
184 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
15. These changes may require EzOPC to be restarted. Close the EzOPC
program and carry out the restart from the start menu. EzOPC can be
accessed via the default setting Programs -> Festo Didactic -> EzOPC
V4.9.2 .
16. Minimise the EzOPC window.
17. If your PLC program is correct, the indicator light H1 is illuminated if
the station is in the initial position.
18. If PLC program still contains errors, then the on-line view in STEP 7
will support you ideally during fault finding. Call up the program
module , in which you suspect the fault and activate Monitor in the
Test menu. You can now monitor in parallel with simulation, which
PLC program sections are or are not being executed.
9. This is how you use COSIMIR® PLC in PLC programming
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 185
Programming a simple sequence for the Distribution station
A simple sequence is to be programmed for the Distribution station.
The sequence is defined as follows:
1. The swivel drive swivels to the „Succeeding Station“ position, if
workpieces are detected in the magazine and the Start button is
pressed.
2. The ejecting cylinder retracts and ejects a workpiece from the
magazine.
3. The swivel drive moves to the „Magazine“ position.
4. The vacuum is switched on. If the workpiece is reliably picked up, a
vacuum switch switches.
5. The ejecting cylinder extends and releases a workpiece.
6. The swivel drive moves to the „Succeeding Station“ position.
7. The vacuum is switched off.
8. The swivel arm moves to the „Magazine“ position.
The technical documentation for the station is to be used, such as
circuit diagrams and the symbols table. You will find these in COSIMIR®
PLC Assistant.
• Represent the control task in function chart according to
DIN EN 60848.
• Program the control task in sequential function chart.
• Test the PLC program with the simulated process model.
9.5
Example
Exercise
Ancillary conditions
Your task
9. This is how you use COSIMIR® PLC in PLC programming
186 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Implementation using the programming system STEP 7 and the Soft
PLC S7-PLCSIM
1. Start COSIMIR® PLC .
2. Load the Distribution process model, controlled via the external PLC.
3. Refer to the technical documentation to find out which process
components are used and what the designations of the components
are in the circuit diagram.
Open the on-line help to do so and activate Help with the Work Cell
in the Help menu.
You will find the required information in the chapter „Technical
Documentation“.
4. Formulate the control task in function chart.
9. This is how you use COSIMIR® PLC in PLC programming
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 187
Station in initial position andpart in magazine and Start button
Function chart to DIN EN 60848 (IEC 60848)
1Start
2Swivel arm
to“SucceedingStation” pos.
Swivel arm to“Succeeding Station” position
Swivel arm in “Succeeding Station” position
Swivel arm in “Succeeding Station” position
Workpiece not picked up
4Swivel arm
to“Magazine”
position
8Swivel arm
to“Magazine”
position
6Swivel arm
to“SucceedingStation” pos.
5Pick up
workpiece
7Deposit
workpiece
3Eject
workpiece
Magazine slide forward(ejecting cylinder to retract)
Magazine slide back(ejecting cylinder to extend)
Vacuum OFF
Swivel arm to“Magazine” position
Swivel arm to“Magazine” position
Swivel arm to“Succeeding Station” position
Vacuum ON
Workpiece ejected
Swivel arm in “Magazine” position
Swivel arm in “Magazine” position
Workpiece picked up andmagazine slide back
Function chart for the control task
Result
9. This is how you use COSIMIR® PLC in PLC programming
188 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
5. Create the symbols table for the control task.
Take the required inputs/outputs from the general symbols table for the
Distribution station. You will find the symbols table on the on-line help
for the work cell.
Symbol Address Data
type
Comment
1B2 I 0.1 BOOL Ejecting cylinder extended
1B1 I 0.2 BOOL Ejecting cylinder retracted
2B1 I 0.3 BOOL Workpiece picked up
3S1 I 0.4 BOOL Swivel drive in magazine
position
3S2 I 0.5 BOOL Swivel drive in succeeding
station position
B4 I 0.6 BOOL Magazine empty
S1 I 1.0 BOOL Start button
1Y1 O 0.0 BOOL Ejecting cylinder to retract
(magazine slide advanced)
2Y1 O 0.1 BOOL Switch on vacuum
2Y2 O 0.2 BOOL Switch off vacuum
3Y1 O 0.3 BOOL Swivel cylinder to magazine
position
3Y2 O 0.4 BOOL Swivel cylinder to
succeeding station position
6. Start STEP 7, i.e. the SIMATIC Manager respectively.
Result
9. This is how you use COSIMIR® PLC in PLC programming
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 189
7. Create a project for the control task.
8. Create the PLC program and store it.
9. Open S7-PLCSIM by clicking onto Simulate Modules under Options
in the SIMATIC MANAGER.
10. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto
the MRES button in the CPU 300/400 window.
9. This is how you use COSIMIR® PLC in PLC programming
190 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
11. Load the PLC program to S7-PLCSIM. To do so, mark the Modules
folder and then activate Load in the Target System menu.
12. Start S7-PLCSIM by clicking onto the box next to RUN in the
CPU 300/400 window.
13. Start the simulation of the process model by clicking onto Start in
the Execute menu.
With the starting of the process model simulation, the communication
program EzOPC is also started. If EzOPC is started, both communication
users - S7-PLCSIM and the simulation of the process model – must
already be active. Only then will the communication links be correctly
set up.
Note
9. This is how you use COSIMIR® PLC in PLC programming
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 191
14. Carry out the settings in EzOPC.
Click onto the EzOPC button in the Start bar to open the EzOPC
window.
Click onto Communication Setup in the Configuration menu.
Carry out the necessary settings.
In the EasyPort section, select Not connected for EasyPort 1.
Select Installed in the section PLCSIM for STEP 7 PLCSIM V5.x.
Accept the preset values 0 and 32 for Start Byte and End Byte
without changing them, although only the first four bytes are
required.
Select PLCSIM for Connect VirtualPLC to: in the section VirtualPLC.
Click onto OK to confirm your settings.
9. This is how you use COSIMIR® PLC in PLC programming
192 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
15. The changes may require EzOPC to be restarted. Close the EzOPC
program and carry out the restart via the start menu. EzOPC can be
accessed via the default setting -> Festo Didactic -> EzOPC V4.9.2.
16. Minimise the EzOPC window.
17. If your program is correct, you can start the sequence once you have
inserted a workpiece by clicking onto the Start button.
18. If the PLC program still contains errors, the on-line view in STEP 7
will support you ideally with fault finding. Call up the program
module, where you suspect an error. Activate the command Monitor
the Test menu. You can now monitor, in parallel with the process
simulation, which PLC programs are or are not being executed.
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 193
COSIMIR® PLC supports you in numerous ways during systematic fault
finding on a simulated system.
The systematic procedure, the working aids and diagnostic systems
used for this and the know-how you acquire, can be applied to any
system.
Load a process model in COSIMIR® PLC . A fault has been previously set
on this process model. You can now control and monitor the process
model as it is being simulated. Analyse the fault behaviour and
determine the cause of the fault. When you have found the cause,
eliminate the fault by entering the cause of the fault in the window
provided. If you have identified the cause of the fault, then the process
model will operate correctly during the next simulation run.
• The selected process model is loaded and a fault set in the process
model by an authorised person.
• The fault simultation mode is active.
• The selected process model is controlled via the internal PLC. A
correct PLC program is available and the sample program is
automatically loaded to the internal PLC.
You can impart these training aims with the use of COSIMIR® PLC :
• Systematically repairing a system after a fault has occurred.
• To familiarise students with and apply a general procedure for
systematic repair work in the event of a fault.
• To acquire information regarding the mode of operation of a system
and system components from technical documentation.
10. This is how you carry out systematic fault finding on
a simulated system
Prerequisite
10.1
Training aims
Main training aim
General training aims
10. This is how you carry out systematic fault finding on a simulated system
194 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
• To determine the actual status of a system after a fault has
occurred.
• To carry out systematic fault finding on PLC controlled
electropneumatic systems.
• To become familiarised with and apply a strategy for fault finding on
PLC controlled electropneumatic systems.
• To carry out a fault analysis.
• To know the typical causes of faults.
• To document faults.
• To make targeted use of diagnostic systems.
• To familiarise students with the working aids for fault finding.
The basic prerequisite for systematic fault finding and corrective
procedures is to understand the system. Only if you understand the
system, its structure and function can you carry out corrective
procedures.
Eliminating faults by means of systematic corrective procedures.
The following methods have proved successful with systematic fault
finding and corrective procedures:
• Familiarisation with the system
• Systematic repair work after a fault has occurred
• Systematic determination of the actual status of the system
• Systematic fault finding in general
• Systematic fault finding for PLC controlled systems
Familiarise yourself with the system by:
• Investigating the system.
• Analysing the system documentation.
• Understanding the product and the processing technology.
• Conducting informative discussions with system operators.
10.2
Methods
Method: Familiarisation
with the system
10. This is how you carry out systematic fault finding on a simulated system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 195
In the event of an inadvertent interruption of the process, corrective
procedures are to be carried out according to the following schematic
representation:
REQUIREDstatus
ACTUALstatus
Faultdiagnosis
Faultfinding
Faultlocated
YesNo
Correctiveprocedures
Recom-missioning
Productionsystem
Com-parison
Systematic corrective procedures
In the event of a fault signal, the actual status of the system is to be
established first.
Once the actual status has been determined and compared with the
required status, the actual fault finding starts. The source of a fault is
often found during this comparison if the fault
• is visible (e.g. mechanical damage on a signal generator)
• is audible (e.g. leakage on a valve)
• is detectable by suspicious odours (e.g. scorching of a cable).
Method: Systematic
corrective procedures after
a fault has occurred
10. This is how you carry out systematic fault finding on a simulated system
196 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
If this is not the case, the fault can be found and eliminated by means of
systematic fault finding.
Once a fault is found, it is not enough to merely correct it. It is also
necessary to establish the cause of the fault. A list of faults is is helpful
for this and this should be stored in the system. This list describes all
the faults and their causes.
With the help of a fault list, it is possible to determine whether damage
or faults occur regularly. In this way, it is possible to identify weak areas
in the system. Once these are established, it is advisable to technically
improve the system.
10. This is how you carry out systematic fault finding on a simulated system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 197
First, the actual system status must be determined in the event of an
error message. Several options are available for this:
Establishing the actual status
Step 1 Determining the fault
behaviour of the system
– No start
– Standstill during process step
– Faulty process sequence
– Work result wrong
Step 2 Establishing the actual status
of the system
– Status displays (LED) on the system components:
– Current mode of operation
– Ready status
– Signal status of signal generators
– Switching status of control elements
– Switching status of PLC input/outputs
– Visible damage
– Audible damage
– Damage detectable by odour/smell
– Screen:
– Error message, diagnostic message
– Status information
– Machine status display
Method: Systmatically
determining the actual
system status
10. This is how you carry out systematic fault finding on a simulated system
198 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
The basis for systematic fault finding is again the desired/actual value
comparison.
Investigating possiblesources of faults by meansof testing or measurementprotocols
Determining ofACTUAL status
Comparison withREQUIRED status
Elimination of faultand recommissioning
Result
YES
(fault found)
NO
(fault not found)
Establishing possibleerror sourcesa
– Mechanical faults– Pneumatic faults– Hydraulic faults– Electrical faults
Overview of systematic fault finding
Method: Systematic fault
finding in general
10. This is how you carry out systematic fault finding on a simulated system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 199
Every controller functions on the principle of signal input, signal
processing and signal output.
Systematic fault finding for PLC controlled systems is based on this
structure.
A desired/actual value comparison enables you to narrow down the
area of the fault within the process sequence. Investigate possible
causes of faults by checking the components in the direction of the
signal and energy flow, starting from the fault location.
Method: Systematic fault
finding for PLC controlled
systems
10. This is how you carry out systematic fault finding on a simulated system
200 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
Structure Working aids Possible error sources
Fault has occurred in the system
Establishing the actual status
Comparison of actual status with
desired status
Checking the electrical energy
supply
Voltage tester – Voltage supply switched off
– Voltage supply to high or too low
Checking of sensor Voltage tester
LED
– Sensor incorrectly adjusted
– Sensor mechanically displaced
– Sensor faulty
Monitoring of PLC input LED – PLC input module faulty
– Cable break between sensor and PLC
input
Checking of PLC LED
Programming and
testing unit
– PLC faulty
– No voltage applied
Checking of PLC output LED – PLC output module faulty
Checking of control elements Voltage tester
LED
Manual override
– Control element mechanically faulty
– Control element electrically faulty
– Cable break between PLC output and
control element
Checking of drive Visual inspection – Connections mixed up
– Loss of electrical connection
Checking of pneumatic or
hydraulic energy supply
Pressure gauge – Energy supply not switched on
– Leakage in network
Systematic fault finding of PLC controlled systems
10. This is how you carry out systematic fault finding on a simulated system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 201
COSIMIR® PLC supports you with the following during the monitoring
and analysis of the actual system status:
• Simulation of the process model and execution of the PLC program
via internal PLC.
• Window for PLC inputs/outputs: Display of PLC input/outputs.
• Window for manual operation: Display of process activities and
process statuses.
• Window for fault localisation: Input and elimination the cause of the
fault.
• COSIMIR® Assistant: Provides information on-line regarding the
process model, such as circuit diagram or function chart.
Finding and eliminating faults in the Distribution station
A fault has occurred in the course of the sequence of the Distribution
station. Eliminate the fault by means of systematic corrective
procedures.
10.3
This is how COSIMIR® PLC
supports you
10.4
Example
Exercise
10. This is how you carry out systematic fault finding on a simulated system
202 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
1. Load the Distribution process model with the set fault. The process
model is controlled via the internal PLC.
2. Ensure that the Fault Simulation mode is active.
3. Put the process model into the initial position by clicking onto Work
Cell Initial Position in the Processing menu.
4. Now start the simulation of the process model. To do so, click onto
Start in the Execute menu.
5. Operate the process using the pushbuttons and switches of the
control console.
Implementation
10. This is how you carry out systematic fault finding on a simulated system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 203
6. A fault has occurred during execution, which stops the process.
10. This is how you carry out systematic fault finding on a simulated system
204 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
7. Refer to the technical documentation to establish the correct
process execution. Open the on-line help for the process model by
clicking onto Help with the Work Cell in the Help menu.
You will find the required information in the chapters „The
Distribution Station“ and „Technical Documentation“.
8. Determine the actual status of the process and compare it with the
required status, thereby narrowing down the area of the fault
location within the process.
10. This is how you carry out systematic fault finding on a simulated system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 205
The fault is a stoppage during the process sequence. The process step
„Move swivel arm to magazine position“ is not executed. Possible
causes of the fault are: The swivel cylinder and its valve actuation or
possibly also the sensors, which should trigger the movement of the
swivel cylinder.
9. We recommend that you check the energy flow, starting from the
sensors through to the swivel cylinder. It is of course possible to
proceed in reverse and to check the signal and energy flow from the
swivel cylinder to the valve via the PLC to the sensor.
10. Find out which sensor signals need to be applied in order for the
swivel arm to move to the magazine position. Use the function chart
and allocation list from the on-line help for the Distribution work
cell.
If the reed switch 1B1 and the end position switch 3S2 are actuated, the
swivel arm should move to the magazine position.
Result
Result
10. This is how you carry out systematic fault finding on a simulated system
206 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
11. Check the switching status of the reed switch 1B1 and the end
position switch 3S2.
Two options are possible.
Evaluate the LED in the process model. The designation of the
respective component is displayed as soon as you click onto the
LED.
Or check the signal status of the sensors in the Manual Operation
window by clicking onto Manual Operation in the Execute window.
The LED of the reed switch 1B1 is illuminated and the sensor therefore
switches.
Result
10. This is how you carry out systematic fault finding on a simulated system
© Festo Didactic GmbH & Co. KG • COSIMIR® PLC 207
12. Check the PLC input 1B1 connected to the sensor by opening the
PLC Inputs window.
Click onto Inputs/Outputs in the Extras menu and select Display
Inputs.
The Inputs window is displayed.
A 0-signal is applied at the PLC input STATION_1B1, even though the
sensor 1B1 switches.
You therefore suspect that the cause of the fault is a cable break at the
PLC input 1B1.
Result
10. This is how you carry out systematic fault finding on a simulated system
208 © Festo Didactic GmbH & Co. KG • COSIMIR® PLC
13. Open the Fault Localisation window to eliminate the fault.
Click onto Fault Localisation in the Execute menu to do so.
Then double click onto No fault on the line PLC input 1B2.
Select Cable Break in the list of options.
The simulation of the process model is continued correctly. The cause of
the fault has been correctly identified and eliminated.
Result