modular Mechatronic System "SSC2P2HV2 " USER & SOFTWARE MANUAL

modular Mechatronic System "SSC2P2HV2 "

USER & SOFTWARE MANUAL

Version 01.10.2014

modular Mechatronic System SSC2P2HV2 - User Manual

USER MANUAL SSC2P2HV2 V01.10.2014.doc Page 2 of 76



Table of content

USER MANUAL ................................................................................. 6

About this manual ........................................................................... 6

Tools required ................................................................................ 7

Safety issues/ Intended use and possible misuse .............................. 8

Removal of transportation safety devices .......................................... 9

First time or re-installation at final location ....................................... 10

Unpacking and checking for damages ......................................... 10

Assembling and separating the stations ....................................... 11

Cable, hose and connector marking ............................................. 12

Settings / Parameter / Password protection ..................................... 12

Maintenance .................................................................................... 13

System overview .............................................................................. 14

Touch Panels ............................................................................... 14

Emergency stop / Safety concept ................................................. 15

Resetting the EMERGENCY STOP ............................................. 16

Unit designations .......................................................................... 17

Functional Units and workpieces used ............................................. 18

Workpieces ................................................................................... 18

Service Unit (= pneumatic air inlet)............................................... 18

Magazine Units ............................................................................. 18

Belt Conveyor ............................................................................... 18

Sorting Unit................................................................................... 19

Handling Unit ................................................................................ 19

Pneumatic Press .......................................................................... 20

ASRS ........................................................................................... 20

Manual transfer device ................................................................. 21

The control of the mechatronic system ............................................ 22

Technical Data ................................................................................. 23

Electrical connections overview: ...................................................... 24

Primary power connections (mains cable of power supplies) ....... 24

Connections between Functional Units and controls (PLCs) ........ 24

Connecting an Ethernet (ProfiNet) switch: ................................... 25

System operation ............................................................................. 26



Pre-operation checklist ................................................................. 26

Powering ON ................................................................................ 26

Powering OFF .............................................................................. 26

Quick Start - basic operation of system/stations .............................. 27

System setup and functional grouping ............................................. 35

Section 1: Magazine and Testing ................................................. 35

Section 2: Handling ...................................................................... 35

Section 3: Press ........................................................................... 36

Section 4: ASRS (Automatic Storage and Retrieval System) ....... 36

Operating modes & step sequences ................................................ 37

Operating Mode No operation .................................................... 37

Operating Mode Manual ............................................................ 38

Operating Mode Automatic stop ................................................. 38

Operating Mode Automatic running ........................................... 38

PLC program steps Magazine and Testing (PLC 1) ..................... 39

PLC program steps Handling Unit (PLC 2): .................................. 39

PLC program steps Press (PLC 2): .............................................. 40

PLC program steps ASRS (PLC 2): ............................................. 40

Alarms and messages ..................................................................... 41

List of alarms (PLC 1) ................................................................... 42

List of alarms (PLC 2): .................................................................. 43

System Touch Panel Station 1 ...................................................... 45

Start screen .................................................................................. 45

Main screen (Menu) ..................................................................... 45

Alarm list + history ........................................................................ 47

Unit screens (for all sections) ....................................................... 48

Statistics screen: .......................................................................... 49

Parameter screens ....................................................................... 49

Main parameter screen ................................................................ 49

Parameter screen for magazine and testing ................................. 50

System screens ............................................................................ 51

System screen for TP177 settings ................................................ 51

System screen for user management ........................................... 51

System Touch Panel Station 2 ...................................................... 53

Start screen .................................................................................. 53



Main screen (Menu) ..................................................................... 53

Alarm list + history ........................................................................ 55

Main unit screen ........................................................................... 56

Unit screens for all sections of station 2: ...................................... 56

Unit screen for shelf display and management:............................ 58

Statistics screen ........................................................................... 58

Parameter screens ....................................................................... 59

Main parameter screen ................................................................ 59

Parameter screen for Handling Unit ............................................. 60

Parameter screen for ASRS ......................................................... 60

System screens ............................................................................ 61

System screen for TP177 settings ................................................ 61

SOFTWARE MANUAL ..................................................................... 63

Purpose ........................................................................................ 64

Programming language ................................................................ 64

Using the STEP 7 Manager .......................................................... 64

Layout and line compartments ..................................................... 66

Software structure ........................................................................ 66

Operating block OB1 .................................................................... 67

Operating block OB100 ................................................................ 67

Data block DB1 ............................................................................ 67

Data block DB4 ............................................................................ 67

Data block DB8 ............................................................................ 68

Data block DB47 .......................................................................... 68

Basic group Program organization FC01H................................ 68

Basic group Inputs FC10H ........................................................ 68

Basic group Alarms FC20H ....................................................... 69

Basic group Common functions FC30H .................................... 70

Basic group Manual mode FC40H ............................................ 70

Basic group Automatic mode FC50H ........................................ 71

Basic group Device control FC60H ........................................... 73

Basic group Communication FC70H ......................................... 73

Basic group Human machine interface FC80H ......................... 74

Basic group Outputs FC90H ..................................................... 74



USER MANUAL

About this manual

In order to operate the mechatronic system properly and troubleshoot it if necessary, it is essentially to read this user manual thoroughly. We strongly recommend also reading the accompanying standard technical documentation of the individual functional modules. Some of these functional modules are modified within this specific application. In this case the changes are explained in this manual. These technical modifications are also represented in the customized diagrams (i.e. electrical diagrams) provided with the system. Please refer to these for complete information.

Without having read the manuals it will be very difficult to understand the system fully and grasp why it behaves a specific way in a situation. Therefore it is cordial to have a good understanding of the processes behind the system, meaning to know how the system behaves when it is functioning properly. Without this basic knowledge it will be very difficult, if not impossible to distinguish between proper functions and faults and therefore unable to carry out troubleshooting.

In the manual you will find some symbols besides the text. These symbols highlight especially important text passages.

Very important notice / safety related information

Important / useful information for working with the equipment

[Manual] Button on touch panel or computer screen



Tools required

Some or all of following tools may be required to install the mechatronic system and to carry out adjustments. They are not provided with the mechatronic system but can be obtained additionally.

Set of Allen keys Set of spanners Set of screwdrivers

Digital Multimeter Hose cutter



Safety issues/ Intended use and possible misuse

The provided equipment is intended for training purposes in mechatronics and PLC programming only.

It is designed to be altered within certain limits by the trainer or trainees if wished.

Changes must only be carried out by skilled personnel or by trainees under the supervision of trainers.

During training a trainer familiar with the system must be present.

The equipment is only to be used indoors within the temperature limits of +10 to +40C and humidity limits of 20 to 70% relative humidity.

The system is rated for a primary power supply of 100H240 V AC, 50/60 Hz. The secondary voltage level is 24 V DC. Do not exceed these voltage ranges.

Static electricity may cause damage to the product. Adequately protect against static electricity during installation and operation.

While exercising on the system make sure you do not have any lose cables that may get in contact with each other or parts of the system. They may cause shortcuts resulting on equipment damage.

The system must not be used for industrial purposes, such as production of any goods.

Always turn off the power before performing any wiring, even if it is "only" on the 24 V DC side of the control. Ignoring that advice may result in electrical shock or damage to the equipment.

Always use proper functioning measuring devices when working on the system.

Air hoses must be of proper size and suitable for the working pressure.

Never use frayed, damaged or deteriorated hoses. Use only proper type and size of hose end fittings and connections.

Avoid free hose ends - they will whip and may cause injury.

Make sure that hoses are fully depressurized before disconnecting them.



Never play with compressed air. Do not apply it to your skin or direct an air stream at people. Never use it to clean dirt from your clothes. When using it to clean equipment, do so with extreme caution and use eye protection.

Never turn the arm of the Handling Unit manually without removing the motor relays first. Ignoring this precaution may result in damage of the connected on-board control electronics.

Never move the axes of the ASRS manually without removing the motor relays first. Ignoring this precaution may result in damage of any connected control electronics or PLC.

Removal of transportation safety devices The axes of Handling Unit and ASRS are secured for transportation to prevent any damage. Remove these transportation safety devices before operating the system.

Handling Unit: Remove cable tie. Do not remove any further items.

ASRS: Remove the 3 screws marked in the image left. Then remove the AL-profile portal (marked with red tape) which is mounted to stabilize the axes of the ASRS.



First time or re-installation at final location

The mechatronic system is shipped in whole by Christiani ex-works directly to the customer. This reduces on-site installation to a minimum. After having received the system from Christiani proceed with the following steps:

Unpacking and checking for damages

Check packaging for any damages.

In case the packaging is damaged take photos for later evidence.

Unpack/unwrap the goods carefully and remove any packaging material completely.

Remove any boxes with accessories from the system.

Check the system again visually for any damages.

In case of any damages take photos for later evidence.

Remove the clearly marked transportation safety locks which are used at ASRS and Handling Unit.

Check pneumatic hoses and electrical cables for any damages; in case there are any get skilled personnel to determine level of damage and take suitable action.

Check, if you have received all goods within the scope of delivery.

Make sure no small parts are hidden between packaging material.

Plug in all connecting cables between PLC and functional units.

Unpack the workpieces (cube halves) from the accessories boxes and fill them into the magazine units. Take care to place them into the proper magazine, since the workpieces and magazines are different.



Assembling and separating the stations

The mechatronic system consists of two individual stations:

Station 1 consists of: 1 base plate, 1 Pneumatic Service Unit, 2 Magazine Units, 1 Belt Conveyor, 1 Sorting Unit, 1 PLC, 1 HMI Operator Panel (with touch panel, EM-stop and Quit button)

Station 2 consists of: 2 base plates permanently connected, 1 Pneumatic Service Unit, 1 Pneumatic Press, 1 Handling Unit, 1 ASRS, 1 PLC, 1 HMI Operator Panel (with touch panel, EM-stop and Quit button)

Both stations can be mounted on trolleys (optional). They can be physically separated and either be operated together or individually. In order to operate the complete mechatronic system it is required to have both stations properly mechanically and electrically connected.

Mechanical connection between base plates of Station 1 and Station 2:

Stations disconnected Stations connected

Assembling the slides of the Sorting Unit:

The slides of the Sorting Unit have been removed for transportation of the system. Before using the system, please mount them. They are fixed to two poles of the Belt Conveyor by means of two screws and hammer nuts.



Cable, hose and connector marking

Some cables may have been removed for transportation to avoid damage during shipping.

All cables, hoses and connectors are marked in a way which allows to easily identify the destination of the cable or hose. For further information please refer to the electrical diagrams.

As a general rule a cable labeled -W1 always leads to a connector -X1, a cable labeled W2 always leads to a connector X2.

Make sure, that the unit designations (i.e. +PPN) do agree

Settings / Parameter / Password protection

The program and parameters of the system are protected. They are accessible via the touch panel of the system.

LOGIN: Admin

PASSWORD: 58030



Maintenance

The mechatronic system respectively its functional units do not need much maintenance. However, when working with the system you may need to fine-adjust one or the other unit for proper positioning or aligning of workpieces. The same applies with adjustments regarding piston movement of the cylinders and tension of toothed belts. These topics should be covered by the teacher during training lessons.

Check from time to time, if the spring pins are still firmly inserted into the lower cube halves. For more information see chapter "Overview - workpieces".

No maintenance at all is needed with regards to the PLC. Nevertheless you should observe the cables for damages, especially the primary power cables, since they carry a dangerous voltage level. If for any reason cables get damaged contact an electrically competent person to carry out the required work or replace the cable immediately with an equivalent new one. Make sure to disconnect the affected device from any power source before starting with repairs.

The only spots where maintenance work may be required are metallic surfaces such as:

cylinder rods (i.e. Handling Unit, Pin Unit)

axles (i.e. ASRS)

gears and spindles (i.e. Handling Unit, ASRS)

guide rods and guide rails (i.e. Handling Unit, ASRS)

Keep surfaces clear from rust and dirt. Clean them on a regular basis and cover the surfaces after cleaning with a common rust preventive lubricant.



System overview

The Mechatronic System "SSC2P2HV2" consists of two individual stations. A station always consists of T-slotted base plate(s) which can be optionally mounted on trolleys with wheels. On the base plate(s) different individual functional modules, such as Service Units, Belt Conveyors, etc. are mounted.

Touch Panels

The mechatronic system includes two touch panels. When following instruction or looking at control elements make sure you are looking at the proper touch panel.

1) System touch panel (located at station 1)

2) System touch panel (located at station 2)



Emergency stop / Safety concept

Since the system consists of two stations which can be operated independently it also features two independent safety circuits. Thus the system has two emergency stop buttons (one at each operator panel). Each emergency stop only affects its own station, even if the stations are connected and the system is operated as one.

That means: pressing the EM-stop at station 1 will only shut off station 1, pressing the EM-stop at station 2 will only shut off station 2.

If an EM-stop is activated on one station and there is an ongoing process on the other station, it will continue until completion.

The status of the safety circuit can be seen on the safety relay:

EM-stop pressed EM-stop released EM-QUIT pressed = Safety circuit OK

EM-Stop EM-QUIT (blue)



Resetting the EMERGENCY STOP

After an EMERGENCY STOP occurrence the system needs to be reset.

Do the following steps:

Make sure the reason for the emergency stop has been removed and the system is in proper condition.

Release the EM-Stop button

Press the blue EM-QUIT button on the system operator panel

If there is no other fault present, the system is now ready to be started again.




Unit designations

All functional units within the system have a unique designation that allows to identify them, mainly in the context of the electrical diagrams, but also in the context of the PLC program. These designations are labeled at each unit. They are also labeled at cables, so it is very easy to identify the target a cable leads to. The list below shows the designations.

+MAG1 Magazine Unit 1

+MAG2 Magazine Unit 2

+BC Belt Conveyor on station 1

+SU Sorting Unit (Testing and Sorting)

+HU Handling Unit (Manipulator)

+PPN Pneumatic Press Unit

+ASRS_HA Automatic Storage Retrieval System, Horizontal Axis

+ASRS_VA Automatic Storage Retrieval System, Vertical Axis

+ OP Operator Panel

+CTRL Control / PLC board

+PS Power Supply

The complete part designation consists of:

=system+location-function:connection

i.e. =mMS+CTRL1-F1:A1

labels the terminal A1 of the safety relay K1 on control 1 of the complete mechatronic system mMS.



Functional Units and workpieces used

Workpieces

The system uses two types of cube halves as workpieces. The lower cube halves have already pins inserted and are stored in MAG1. Check from time to time that, if the spring pins are still firmly inserted into the lower cube halves. The upper cube halves have no pins inserted and stored in MAG2.

Service Unit (= pneumatic air inlet)

The Service Unit comprises of a pressure regulator valve with 3/2-way valve, pressure gauge, adjusting knob (twistable/lockable) and water separator. It is completely fixed upon one mounting plate, which enables its easy and flexible mounting on an aluminium profile plate both stand-alone and together with additional functional units.

The inlet for pneumatic air is located at the Service Units of station 1 and 2. Connect the pneumatic compressor's outlet via a suitable hose with the 6 mm quick coupling connector of the Service Unit.

The provided air pressure at the inlet may not exceed 10 bar.

Magazine Units

Up to 10 stacked workpieces can be accommodated in the Magazine Units (MAG1 and MAG2). Always the lowest workpiece is pushed out of the stack through a pneumatic cylinder, which is controlled by a 5/2 directional control valve. A limit switch controls the filling level of the magazine.

Belt Conveyor

The functional assembly Belt Conveyor (BC) on station 1 consists of a 680 mm long and 50 mm wide belt line. At the end of the belt line a fiber optic sensor with amplifier is mounted to detect arriving workpieces and stop the belt motor. By means of a reversing contactor circuit the Belt Conveyor can be moved in two directions (forward/reverse).



Sorting Unit

The functional assembly Sorting Unit (SU) allows to test workpieces, determine their material properties and orientation and sort them onto three slides if required. To serve this purpose it consists of six sensors and three pneumatic cylinders. These sensors are: ultrasonic (analog), optical and inductive.

The ultrasonic sensor detects when a workpiece on the belt conveyor reaches the inspection section. It triggers a signal to stop the belt shortly after workpiece detection. The ultrasonic sensor needs to be properly programmed and its measuring range set. See technical datasheet of sensor or technical documentation of Sorting Unit for more information.

The optical sensor detects whether the material is light or dark (light = white/aluminium, dark = black). The inductive sensor establishes whether the workpiece is metallic or non-metallic. The optical sensor of the Testing Unit needs to be programmed for proper operation. Refer to the Functional Unit's technical documentation and the datasheet of the sensor for more information.

The Sorting Unit is designed to be mounted sideways at the belt conveyor (+BC1). It can be fitted both to the left or right side of the belt conveyor (viewed in direction of travel). However it is essentially that it is mounted in such a way that, in direction of travel, the workpiece arrives first at the ultrasonic sensor. The height of the Sorting Unit can be adjusted to fit the height of the Belt Conveyor (i.e. 100 mm or 115 mm).

Afterwards testing the belt is started again. Depending on the recipe for the complete cubes, unwanted cube halves are sorted onto three slides. Workpiece detection at the slides is done via three optical sensors.

Handling Unit

The Handling Unit (HU) on station 2, allows to carry out pick-and-place tasks. Workpieces are picked up from one place and deposited at another place. The available three-axis manipulator covers a work area of 270. In this work area any number of positions can be struck. The actuator of the X-axis takes place over a direct current motor with integrated speed/position sensor, which can be controlled with the appropriate evaluation electronics and a PLC. The left and right-hand motions of the actuator are achieved with a reversing contactor circuit. The twist-proof double acting pneumatic cylinder with a range of 60 mm moves the Y-axis to and fro. The Z-axis is moved with a twist-secure double acting pneumatic cylinder with a range of 100mm. For pick-up of the workpieces the manipulator is furnished with a vacuum sucker and a Venturi nozzle.



Note: The Handling Unit requires a PLC with two fast counter inputs in order to be able to evaluate the speed sensor signals.

Caution!

Never move the arm of the manipulator by hand without releasing the relays before. Inducted voltage may destroy the motors electronics and the speed sensor electronics.

Pneumatic Press

Two workpieces (cube halves) can be processed in the Pneumatic Press (PPN). This unit is designed to press two cube halves together to produce one complete cube. Workpieces are placed subsequently by an upstream functional unit in the drawer of the Press Unit. The drawer pulls the pieces to be processed into the press room. The safety door closes and the press cylinder begins to extend. The two cube halves are pressed together with a force of around 220 N (at 4 bar). At last the safety door opens and the workpieces are pushed out of the press room and are ready to be picked up.

The press has a workplace that is closed completely on three sides and by a safety door on the fourth side. Safety screens made of Plexiglas enable the observation of the press operation. To achieve the required safety level in stand-alone mode, the Press Unit is equipped with two buttons allowing two-hand operation. In automatic mode, respectively in an integrated environment (station/system) these buttons have usually no functionality.

If the Pneumatic Press is embedded within a bigger system the two-hand operation buttons may not be wired and therefore be redundant.

ASRS

The functional assembly ASRS (+ASRS_VA and +ASRS_HA) consists of a vertical axis (VA), horizontal axis (HA) and a storage rack, which are altogether mounted on two profile plates. The combination of vertical and horizontal axle enables filling the rack in two dimensions. Takeover of workpieces takes place at a predefined transfer position. It can be marked by a twin bore in the positioning bracket of the horizontal axle. In case of any other transfer position the twin holes need to be masked.

From the transfer position the workpiece is moved to an empty compartment of the rack. The carriage of the horizontal axle moves the vertical axle. On the carriage of the vertical axle a double-acting pneumatic cylinder with a fork for taking up workpieces is mounted.



The positioning of both axles is made via holes in the brackets of both axles. These are recognized by fork light barriers. Micro switches detect the end position of the carriages. One of each micro switch serves for hard stop (hard-wired) the other one delivers a signal to the PLC to stop motion. The axles consist each of a linear guide on which a bearing carriage is moved. The drive for the vertical axle takes place through a spindle, for the horizontal axle through a belt. The direct current geared motors used are operated by a reversing contactor circuit.

There are seven storage spaces on four levels each - makes it overall 28 storage spaces available. The workpieces must have a square base of 50x50 mm and can have a height of up to 50 mm.

In addition to the standard equipment, the ASRS may optionally be fitted with an optical transducer located at the rack feeder's fork. It is used for monitoring whether a workpiece is present on the rack feeder. If present, this sensor has a PNP logic.

Caution!

Never move the axes of the ASRS by hand without releasing the relays before. Inducted voltage may destroy any connected electronic device.

Manual transfer device The system is fitted with a manual transfer device which is located at the intersection between station1 and station 2. In single station

mode (stations not connect-ed) place workpieces here manually. The Handling Unit of station 2 will pick up the workpiece from here.

(Image: main screen of touch panel #2)

On system touch panel 2 a flashing button will indicate which workpiece is required next. This can be either a lower cube half (Lower CH) or, if a lower cube half is already present in the press unit, an upper cube half (Upper CH). Place the

required workpiece in the transfer device and press the flashing button afterwards.



The control of the mechatronic system

On both stations of the mechatronic system PLCs and safety devices are present.

The controls (CTRL1 and CTRL2) consist of a PLC DIN rail on which besides the PLC itself different components are mounted, such as terminal blocks, fuse and safety relay. All wires and cables are placed in cable ducts.

For further information on wiring please refer to the electrical diagrams. The PLC hardware consists of a SIMATIC S7 PLC with the following modules:

1 Compact CPU 314C-2PN/DP with integrated digital and analog inputs/outputs, ProfiNet and Profibus DP interface.



The operating voltage of the controls is 24 V DC. The primary power supply is rated @ 90H264 V AC, 50/60 Hz (automatic selection). The primary mains cable is directly led to the insulated power supply thus practically eliminating the risk of unintentional contact with a dangerous voltage level.

Technical Data

Electrical power consumption:

Station 1 in operating condition: approx. 34 VA Station 2 in operating condition: approx. 38 VA

The control part is equipped with a 5 x 20 mm fuse rated @ 1 A T.

Spare fuses are provided with the system.

Pneumatic air consumption:

Complete system in operating condition: approx. 9 l/min.

General data:

Dimensions: 2000 x 550 x 650 mm (length x width x height)

Weight Station 1 (without trolley): 34 kg

Weight Station 2 (without trolley): 48 kg



Electrical connections overview:

The following electrical connections can be found within the system:

Primary power connections (mains cable of power supplies)

Power and signal distribution (safety interlocks)

Connections between Functional Units and PLC

Ethernet connection between PCLs and Touch Panels and between Station 1 and Station 2.

Primary power connections (mains cable of power supplies)

The system comes with three independent power supplies:

2 x for the PLC

1 x for the Ethernet switch

Plug them into 230 V AC power sockets.

Connections between Functional Units and controls (PLCs)

Each functional unit has between one and four cable(s) for electrical connection. These cables run directly from the modules to the PLC. This way of wiring allows maximum flexibility when using the functional units. Each module can be easily detached from the system and used stand-alone, by simply disconnecting the cable(s) and the pneumatic connection.

The cables are labeled with their designation according to the electrical drawings. Please refer to the electrical drawings for more information.



Connecting an Ethernet (ProfiNet) switch:

The systems PLCs are connected to each other via Ethernet/ ProfiNet. The connection can be separated at the Ethernet switch located on station 2. If you need to separate the stations please remove the cable leading to station 1 (marked with a red circle in the image below) and all cables leading to external programming devices (computers).

Image: Location of Ethernet switch

Image: Available ports for external programming devices or external Ethernet/ProfiNet components.

Note: the Ethernet switch has its own power supply, thus requires an own power socket. The power supply of the switch is rated at 100 - 240 V AC.



System operation

Pre-operation checklist

Before you start the system go through the following checklist:

Stations are mechanically properly connected

Stations and units are mechanically aligned to each other

The power cables are plugged into the main power supplies

Pneumatic air is connected to the system and turned on

Main switch at the power supplies are ON

Touch Panel has booted up properly showing Start Screen

Powering ON

In order to operate the system it is necessary to provide all subsystems with electrical and pneumatic power. After having established and checked all required electrical and pneumatic connections:

switch ON mains power at the power supplies

press one or both blue EM-QUIT button (on the operator panels)

switch ON mains power at the air compressor

turn ON pneumatic air supply at the Service Units located on both stations

Powering OFF

After using the mechatronic system:

STOP the system/station by pressing the STOP button on the touch panel(s)

turn OFF pneumatic air supply at the Service Unit located on both stations

switch OFF mains power at the air compressor

switch OFF mains power at the power supplies



Quick Start - basic operation of system/stations Note: Extract (print) pages 27 34 from the complete manual as quick reference sheets.

Behind each touch panel there is a power supply with a mains switch.

Turn ON the main switch to provide the system with electrical power. The PLCs and touch panels should now be powered, the touch panel should boot an after a while show the company logo of Christiani.

Also at the back side of the system there are two pneumatic service units, one at each end. They are pneumatic air inlets and main switches to turn air pressure on/off and set the system air pressure (~ 4 bar).

Switch ON air pressure her by turning the knob at the top of the service unit. Check, if system pressure is on and properly set by means of the pressure gauge fitted to the pneumatic service unit.



Once the control of the mechatronic system has powered up, the screen of the touch panel(s) will show the system start screen.

Press the button [Menu] to display the main menu.

Usually, now the [Quit] button will flash in red, indicating that there is a fault (the safety circuit is not closed).

Menu

.



Reset the safety circuit:

Check, if

the system is in proper condition and safe to operate

one or both emergency stop buttons are pressed, if so release them by gently turning and pulling

press the blue EM-QUIT button

The status of the safety circuit can be seen on the safety relay:

EM-stop pressed EM-stop released EM-QUIT pressed = Safety circuit OK

After having reset (quit) the system, all 3 LEDs at the safety relay should be illuminated green. The [Quit] buttons on the touch panels should no longer flash in red.

If system air pressure is on the vertical axis of the Handling Unit should extend (move upwards).




Line Type / Operation Mode selection

Operation mode selection consists of

Line Type setting (single = stations are run individually / connected = both stations run together)

Automatic / Manual selection

To set the line type press [Parameters] at the bottom screen of the main menu:

Then select the desired setting:

It is important to set the line type properly; otherwise the system will not work but generate error messages.

It is possible to select single, even if the network connection is present. However, if the network connection is disconnected it is necessary to select Single

.



Once the line type is set it is possible to select the operation mode.

Note: Selected buttons are generally highlighted in green showing the current configuration setting or operation mode.

Select the desired operation mode by either pressing the button [Manual] or [Automatic] in the top left corner of the menu.

Manual mode:

In Manual mode it is possible to operate each actuator individually to check its proper function by using the [Extend] / [Retract] or [Forward] / [Backward] buttons. Next to the buttons for the actuators the PLCs out- and inputs are displayed to assist troubleshooting in case an actuator or sensor is not responding.

This applies for both stations in the same way.

Note: Pressing the [Start] button in manual mode has no effect.

.

.



Automatic mode with Line Type connected:

In Automatic mode the [Storage] button must be highlighted (green), otherwise the system will not start, since no task is selected.

Therefore press [Storage] and afterwards press [Start].

The system will now produce cubes and store them in the ASRS. Unwanted cube halves will be sorted out onto the slides.

Note: if the system is in connected mode both station will always have the same mode of operation. It is not possible to select Automatic at one station and Manual at the other.

Automatic mode with Line Type Single Station 1:

The process on station 1 is identical independently of the line type setting. By pressing [Start] the system expels cube halves from the Magazines onto the Belt Conveyor, test/sorts them and moves them finally to the end of the Belt Conveyor. If connected the Handling Unit picks the cube halves up at the end of the Belt Conveyor. In Single mode the workpiece stays at the end of the Belt Conveyor until manual removal by the operator.

As soon as the workpiece is removed the Magazine will expel the next cube half.

.



Automatic mode with Line Type Single Station 2:

In Connected mode the Handling Unit of station 2 automatically picks up a workpiece at the end of the Belt Conveyor as soon as it arrives there.

In Single mode the Handling Unit will pick up workpieces from the transfer device instead of the Belt Conveyor, since station 1 may not be present (physically detached) and therefore neither the Belt Conveyor will be present.

However, since no sensors are available at the transfer device the Handling Unit has no way of knowing, whether a workpiece is there or not. Therefore the processes in Single mode and Connected mode slightly differ.

In Single mode the user needs to place the proper workpiece at the transfer device. The required workpiece is indicated at the touch panel of station 2.

Depending what workpiece is required next, either the [Upper CH] or the [Lower CH] button is flashing in green.

Place the required workpiece in the transfer device and afterwards press the button which is flashing. The Handling Unit will move to the transfer device and pick up the workpiece. The process on station 2 will alternately require a lower and an upper cube half. Once both cube halves are placed in the press the process will continue identically to the way it runs in Connected mode.

Process description:

Press [Automatic] then press [Start] [Lower CH] is flashing

Place lower cube half in transfer device, then press [Lower CH]

Handling Unit picks up and moves lower cube half to Press Unit

[Upper CH] is flashing

Place upper cube half in transfer device, then press [Upper CH]

Handling Unit picks up and moves upper cube half to Press Unit

Cube halves are pressed together in the Press Unit, afterwards picked up by the Handling Unit, moved to the ASRS and stored there.



Own notes:



System setup and functional grouping As explained in the chapters before the mechatronic system consists of the following functional units:

2 Magazine Units

1 Sorting Unit

1 Belt Conveyor

1 Handling Unit

1 Pneumatic Press

1 ASRS

These functional units of the assembly line are program-wise grouped into the following 4 functional sections:

Section 1: Magazine + Testing (Sorting)

Section 2: Handling

Section 3: Press

Section 4: ASRS

Section 1: Magazine and Testing Aluminium and black/white plastic cube halves (= workpieces) are expelled from two magazines to the Belt Conveyor. At the end of the Belt Conveyor an optical sensor signals the arrival of the cube halves. While being transported forward on the Belt Conveyor, the Sorting Unit checks the workpieces for their material properties and orientation. Workpieces with wrong orientation (according to the parameter setting), wrong material or wrong color are expelled from the line onto three slides.

Section 2: Handling The Handling Unit is the central device for workpiece distribution between different sections.

Handling Unit jobs:

Transport lower cube halves from Belt Conveyor to Press

Transport upper cube halves from Belt Conveyor to Press

Transport finished cubes from Press to ASRS (Storage)



Section 3: Press Handling Unit 1 places one of each cube halves in the Pneumatic Press. After the press punching operation is finished the completed cube is picked up by Handling Unit and dropped off at the rack feeder of the ASRS for storing.

Section 4: ASRS (Automatic Storage and Retrieval System) The ASRS can have 2 operating modes: STORAGE and RETRIEVAL In this application only STORAGE mode can be activated. Storage: The rack feeder gets the finished cubes from the Handling Unit and places them in one of the 28 available spaces in the rack shelf. The touch panel provides a specific screen for shelf display and shelf management. This diagnosis screen shows all finished cubes in the rack and allows the operator to manipulate rack occupancy. Retrieval (not used in this application): The rack feeder takes finished cubes from the shelf rack and moves them to a transfer position, where the Handling Unit picks them up and places them somewhere else. This mode is not available in this application



Operating modes & step sequences The system has 4 operating modes, depending on actual safety conditions and operator selection. The operating modes are activated or selected with the following priority:

No operation

Manual

Automatic stop

Automatic running

The operating mode can be selected from the main screen of the operator panel.

Operating Mode No operation The operating mode No operation blocks all movements in case of an emergency stop condition. This mode is automatically activated by hardware interlocks and the PLC if one of the following conditions is true:

Emergency stop button pressed

Safety interlock circuit not closed

Safety relay not activated

In this operating mode, the PLC will set all outputs for valves and drives to LOW signal. Power supply for all valves and drives will be disconnected by hardware interlocks using a specific safety relay. To reset this condition, it is necessary to close the safety interlock circuit:

Remove the reason for the incident and make sure the system is in proper condition again. I.e. check all connections.

Release the EM-Stop button

Press the blue EM-QUIT button on the system operator panel

If there is no other fault present, the system is now ready to be started again.



Operating Mode Manual Manual mode is especially designed for diagnosis and maintenance purposes. All devices can be operated manually from the system touch panel. Manual mode can by activated by pressing the button [Manual] at the main screen of the system touch panel. In manual mode safety interlocks are still operational. All common interlocks for automatic operation are not active.

Operating Mode Automatic stop The PLC switches the operating mode automatically to Automatic stop if the following conditions are all true:

No emergency stop condition

Safety interlock circuit closed and safety relay activated

Buttons [Manual]/[Automatic] are set to [Automatic]

Automatic running not active

Operating Mode Automatic running Automatic mode is designed for a fully automated process. Automatic operation can be started and stopped by the operator at any time. From operating mode Automatic stop, the operator can switch to Automatic running by pressing the push button [Start] at the system touch panels. Pressing the push button [Stop] at the system touch panels will stop the automatic mode immediately. Alarms category 1 will also stop automatic execution. In automatic mode all safety interlocks are operational. All common interlocks for automatic operation are active, too. In operating mode Automatic running all devices on this station are controlled by the following step sequences:



PLC program steps Magazine and Testing (PLC 1)

Step Description

0 Not active

1 Homerun (move all units to home position)

2 Check for moving workpieces in section (in case of workpiece moving in this section the controller jumps to the related step)

3 Wait for enable start (Storage must be activated)

4 Extend magazine cylinder

5 Retract magazine cylinder

6 Move workpiece to checking position

7 Check workpiece for orientation, material and colour

8 Move workpiece to push out position

9 Extend separation cylinder

10 Retract separation cylinder

11 Move workpiece to transfer position

12 Wait for workpiece transfer (transfer position empty)

13 Remove workpiece if the workpiece orientation does not fit with the request from Module 2

PLC program steps Handling Unit (PLC 2):

Step Description

0 Not active



3 Wait for new Job

4 Move to belt conveyor

5 Retract vertical cylinder

6 Generate vacuum

7 Extend vertical cylinder

8 Move to press


10 Release vacuum


12 Move to press


14 Generate vacuum


16 Move to ASRS


18 Release vacuum




20 Move to parking position

21 Move to ASRS (retrieval, not used)

22 Retract vertical cylinder (retrieval, not used)

23 Generate vacuum (retrieval, not used)

24 Extend vertical cylinder (retrieval, not used)

25 Move to belt conveyor extern (retrieval, not used)

26 Retract vertical cylinder (retrieval, not used)

27 Release vacuum (retrieval, not used)

28 Extend vertical cylinder (retrieval, not used)

PLC program steps Press (PLC 2):

Step Description

0 Not active



3 Wait for lower cube halve

4 Wait for upper cube halve

5 Retract pusher

6 Close safety door

7 Extend punch

8 Retract punch

9 Open safety door

10 Extend pusher

11 Wait for workpiece transfer (press empty)

PLC program steps ASRS (PLC 2):

Step Description

0 Not active



3 Wait for new job

4 Move rack feeder to transfer position

5 Wait for cube on fork

6 Move rack feeder to shelf rack

7 Extend fork cylinder

8 Move rack feeder down (set down cube on rack)

9 Retract fork cylinder

10 Move rack feeder to shelf rack

11 Extend fork cylinder



12 Move rack feeder up (pick up cube from rack)

13 Retract fork cylinder

14 Move rack feeder to transfer position

15 Wait for workpiece transfer (fork empty)

Pushing the button [Manual] at the system touch panels will reset the actual step number to zero. The next time Automatic running is used, the step sequence will start with step 1 (automatic homerun) and continue operation depending on existing moving workpieces in the section (decision is made in step 2). It is possible to delete moving workpieces on the related unit screens of the system touch panels (only if automatic is not running).

Alarms and messages The control system generates alarm messages automatically, to help the operator in case of malfunction of equipment and other problems. All movements of devices and workpieces are monitored. If a certain time limit is exceeded, an alarm is generated and a specific text message is displayed at the message screen of the system touch panels. For training purposes the text message function at the system touch panels can be turned off. All alarms are allocated to two categories:

Alarms of category 1 will stop automatic execution

Alarms of category 2 are only displayed indications with some effects on related devices

Most alarms are stored and must be reset by pressing the push button [Quit] at system touch panels. In case of category 1 or 2 alarms there is a flashing red signal on the system touch panels.

Flashing means a new alarm of category 1 or 2 has occurred

Always on means an alarm of category 1 or 2 is still active, but already acknowledged by pressing the push button [Quit].



List of alarms (PLC 1)

No. Text Category

1 Common Safety interlock circuit not closed (Emergency stop)

1

2 Common Communication fault with module 2 (ProfiNet)

1

17 Magazine + Separation Time limit magazine cylinder 1 extend

2

18 Magazine + Separation Time limit magazine cylinder 1 retract

2

19 Magazine + Separation Time limit magazine cylinder 2 extend

2

20 Magazine + Separation Time limit magazine cylinder 2 retract

2

21 Magazine + Separation Time limit separation cylinder 1 extend

2

22 Magazine + Separation Time limit separation cylinder 1 retract

2


2


2


2


2

27 Magazine + Separation Time limit workpiece moving from magazine to checking position

2

28 Magazine + Separation Time limit workpiece moving from checking position to separation cylinder 1

2


2


2

31 Magazine + Separation Time limit workpiece moving from checking position to transfer position

2

33 Magazine + Separation Magazine 1 empty

2

34 Magazine + Separation Magazine 2 empty

2

37 Magazine + Separation Workpiece height off range

2



List of alarms (PLC 2):

1 Common Safety interlock circuit not closed (Emergency stop)

1

2 Common Communication fault with module 1 (ProfiNet)

1

33 Handling Unit Time limit rotation right

2

34 Handling Unit Time limit rotation left

2

35 Handling Unit Time limit vertical cylinder extend

2

36 Handling Unit Time limit vertical cylinder retract

2

37 Handling Unit Time limit horizontal cylinder extend

2

38 Handling Unit Time limit horizontal cylinder retract

2

48 Handling Unit Rotation axis blocked (no impulses from encoder)

2

49 Press Time limit safety door open

2

50 Press Time limit safety door close

2

51 Press Time limit pusher extend

2

52 Press Time limit pusher retract

2

53 Press Time limit punch extend

2

54 Press Time limit punch retract

2

65 ASRS Time limit horizontal axis forward

2

66 ASRS Time limit horizontal axis backward

2

67 ASRS Time limit vertical axis up

2

68 ASRS Time limit vertical axis down

2

69 ASRS Time limit fork cylinder extend

2

70 ASRS Time limit fork cylinder retract

2

71 ASRS Workpiece not on fork

2

72 ASRS 2

No. Text Category



Workpiece still on fork

73 ASRS Workpiece on fork unknown

2

74 ASRS Limit switch horizontal axis forward

2

75 ASRS Limit switch horizontal axis backward

2

76 ASRS Limit switch vertical axis up

2

77 ASRS Limit switch vertical axis down

2

78 ASRS Horizontal axis has wrong position

2

79 ASRS Vertical axis has wrong position

2



System Touch Panel Station 1 The system touch panels are the main means for diagnosis and parameter setup as well as a device for alarm message display. The panels provide information about current conditions for all sections of the system and are used to edit parameters like positions for encoder controlled positioning devices.

Start screen

Main screen (Menu) The main screen provides the operator with basic information about all sections in the process line.

Menu

.

Shows current recipe for cube production



Push buttons on top:

Automatic (Switches to automatic mode)

Manual (Switches to manual mode)

Start (Start Automatic running)

Stop (Stop Automatic running)

Storage (On/Off for storage line from magazine to ASRS)

L-Test (Lamp test, only working, if light pole present)

Quit (Reset alarms) Alarm Indicators on top:

Alarm category 1

Alarm category 2 Mode (operating mode):

No operation

Manual

Automatic stop

Automatic running WP Ident:

shows the result of the last workpiece examination at testing position

The following results are possible:

o Lower cube halve aluminium o Lower cube halve plastic black o Lower cube halve plastic white o Upper cube halve aluminium o Upper cube halve plastic black o Upper cube halve plastic white

Cube picture on right side shows the current program selection (recipe) for the storage line:

Program for upper cube halves (Aluminium, plastic black, plastic white)

Program for lower cube halves (Aluminium, plastic black, plastic white)



Section overview:

WP = Workpiece moving in section

AL = Section has alarm category 1 or 2 Screen navigation buttons at the bottom:

Messages (screens with alarm list and alarm history)

Units (diagnosis and manual screens for all sections)

Parameter (parameter setup screens)

System (system screen for touch panel)

Alarm list + history (press [Messages] on main screen) The alarm list contains all current alarm messages with alarm numbers. The alarm history provides an alarm message buffer with all previous alarm messages. It contains the message text with time for alarm coming and alarm going off. The size of the alarm buffer is 500 messages. After the buffer is full, the oldest entry will be automatic-ally deleted. Alarm list: Alarm history:

MenuHistory

Messages Menu



Unit screens (for all sections) (press [Units] or press direct unit buttons on main screen) For station 1 there are 2 unit screens available. Switch between screens by using the [NEXT] / [PREVIOUS] buttons.

Screen 1: Magazine Units and Belt Conveyor

Screen 2: Sorting Unit

The unit screens provide the following information and controls:

Actual step number with variable text description

Alarm category 1 or 2 active

Moving workpieces

Clear button (button works only if automatic is not running)

Manual controls (Push buttons for manual mode and indicator lights for diagnosis, O=Output, I=Input)

Actual workpiece height in mm

.

.



Statistics screen: (press [Statistics] on main screen)

The statistic screen allows data analysis by showing the number of stored and removed cubes during a specific time frame. All data are sorted by workpiece materials. To start a new monitoring period all counters can be deleted by pushing the button [Clear All]. Parameter screens (press [Parameter] on main screen) Main parameter screen

Common settings

Show alarm text messages on/off (for training purposes, it is possible to turn alarm text messages off)

.



Line Type (Selection between Single mode = each station works separately and Connected mode = The 2 stations are connected and work together)

The main parameter screen allows the selection of the actual program as follows:

Upper cube halves (Aluminium plastic black plastic white)

Lower cube halves (Aluminium plastic black plastic white)

Program selection is interlocked with moving workpieces on the storage line. To change the actual program settings, it is necessary to empty the storage line between magazine and ASRS or delete all moving workpieces on this line. Specific parameter screens for other sections can be selected from the main parameter screen. Parameter screen for magazine and testing

The parameter screen for magazine and testing allows the following settings:

Time delay for workpieces moving between sensor and testing cylinder in seconds

.



System screens (press [System] on main screen) System screen for TP177 settings

System screen 1 displays actual date and time from the PLC and allows the change of date and time settings. The push button [Control panel] opens a windows setup screen for all basic touch panel settings (see documentation for TP177B). System screen for user management (user level Administrator required)

System screen 2 provides a list of all users with admission to one or several of the following protected levels (groups).

Level 1 - Operator

Level 2 - Advanced operator

Level 3 - Teacher

Level 9 - Administrator

User screen

MenuSystem



Upper levels include permission for lower levels. These levels can be used to protect single input fields, controlling buttons or screen navigation buttons. The setup must be done with WinCC flexible software using the screen editor (see operator manual for WinCC flexible for further information). Login for user level Administrator:

User name: Admin Password: 58030



System Touch Panel Station 2

Start screen

Main screen (Menu) The main screen provides the operator with basic information about all sections in the process line.

Push buttons on top:

Automatic (Switches to automatic mode)

Manual (Switches to manual mode)

Start (Start Automatic running)

Menu

.



Stop (Stop Automatic running)

Storage (On/Off for storage line from magazine to ASRS)

L-Test (Lamp test, only working, if light pole present)

Quit (Reset alarms) Alarm Indicators on top

Alarm category 1

Alarm category 2 Mode (operating mode)

No operation

Manual

Automatic stop

Automatic running WP Ident:

shows the result of the last workpiece examination at testing position

The following results are possible:

Lower cube halve aluminium

Lower cube halve plastic black

Lower cube halve plastic white

Upper cube halve aluminium

Upper cube halve plastic black

Upper cube halve plastic white Cube on right side shows the actual program selection for the storage line:

Program for upper cube halves (Aluminium, plastic black, plastic white)

Program for lower cube halves (Aluminium, plastic black, plastic white)

Section overview

WP = Workpiece moving in section

AL = Section has alarm category 1 or 2 Screen navigation buttons at the bottom:

Messages (screens with alarm list and alarm history)

Units (diagnosis and manual screens for all sections)

Parameter (parameter setup screens)

System (system screen for touch panel)



Alarm list + history (press [Messages] on main screen)

The alarm list contains all actual alarm messages with alarm numbers. The alarm history provides an alarm message buffer with all previous alarm messages. It contains the message text with time for alarm coming and alarm going off. The size of the alarm buffer is 500 messages. After the buffer is full, the oldest entry will be automatically deleted. Alarm list: Alarm history:

MenuHistory

Messages Menu



Unit screens (press [Units] or press direct unit buttons on main screen)

Main unit screen

Specific unit screens for all sections and the shelf display can be selected from the main unit screen.

Unit screens for all sections of station 2:

.

.



The unit screens provide the following information and controls:

Actual step number with variable text description

Alarm category 1 or 2 active

Moving workpieces with Clear button (button works only if automatic is not running)

Manual controls (Push buttons for manual mode and indicator lights for diagnosis, O=Output, I=Input)

Actual position for rotation axis (Handling unit)

.

.



Unit screen for shelf display and management: An additional unit screen shows all finished cubes on the shelf and allows the operator to manipulate shelf occupancy.

Using the push buttons at the shelf and the bottom, the operator can set cubes to and clear cubes from single shelf racks as well as setting/clearing all shelf racks at one time. This screen also shows the number of cubes on the shelf.

Statistics screen

The statistic screen allows data analysis by showing the number of stored and removed cubes during a specific time frame. All data are sorted by workpiece materials. To start a new monitoring period all counters can be deleted by pushing the button Clear All.



Parameter screens (press [Parameter] on main screen)

Main parameter screen

Common settings:

Show alarm text messages on/off (for training purposes, it is possible to turn alarm text messages off)

Line Type (Selection between Single mode = Each station works separately and Connected mode = The 2 stations are connected and work together)

The main parameter screen allows the selection of the actual program as follows:

Upper cube halves (Aluminium plastic black plastic white)

Lower cube halves (Aluminium plastic black plastic white)

Program selection is interlocked with moving workpieces on the storage line. To change the actual program settings, it is necessary to empty the storage line between magazine and ASRS or delete all moving workpieces on this line. Specific parameter screens for other sections can be selected from the main parameter screen.

.



Parameter screen for Handling Unit (press [Handling Unit] on parameter screen)

The parameter screen for handling unit 1 allows the following settings:

4 positions for rotation axis in degree Parameter screen for ASRS (press [ASRS] on parameter screen)

The parameter screen for ASRS allows the following settings:

Maximum number of cubes in shelf (Limit for storage)

.

.



System screens (press [System] on main screen)

System screen for TP177 settings

System screen 1 displays actual date and time from the PLC and allows the change of date and time settings. The push button Control panel opens a windows setup screen for all basic touch panel settings (see documentation for TP177B).



System screen for user management (user level Administrator required)

System screen 2 provides a list of all users with admission to one or several of the following protected levels (groups).

Level 1 - Operator

Level 2 - Advanced operator

Level 3 - Teacher

Level 9 - Administrator Upper levels include permission for lower levels. These levels can be used to protect single input fields, controlling buttons or screen navigation buttons. The setup must be done with WinCC flexible software using the screen editor (see operator manual for WinCC flexible for further information). Login for user level Administrator: User name: Admin Password: 58030

User screen

MenuSystem



modular Mechatronic System "SSC2P2HV2 "

SOFTWARE MANUAL

Version 01.12.2012



Purpose The software manual provides general information about the PLC software application and the interface between PLC and HMI. It does not explain all interlocks and functional correlations in detail. It is intended for students in the field of S7 programming, maintenance- and service personnel. In order to understand this manual, general knowledge of automation technology and S7 programming is required. To use this manual effectively, you should already be familiar with the theory behind S7 programs which is documented in the online help for STEP 7.

Programming language The programming language is STL (STatement List). STL corresponds to the "Instruction List" language defined in the International Electrotechnical Commission's standard IEC 1131-3. STL is the best and most professional of all available languages for PLC programming, because it corresponds directly with the PLC processor commands and allows the programmer to use all available methods and PLC capabilities. The knowledge of statement list instructions and procedures is needed to fully understand the subjects of this manual and comprehend the actual program code.

Using the STEP 7 Manager It is recommended to open and display the project in the STEP 7 project window as reference during study of this software manual. The project window is split into two halves. The left half shows the tree structure of the project. The right half shows the objects that are contained in the object open in the left half in the selected view (large symbols, small symbols, list, or details). At the top of the object hierarchy is the object "ESL01" as the icon for the whole project. It can be used to display the project properties and serves as a folder for networks (for configuring networks), stations (for configuring the hardware), and for S7 programs (for creating software). The objects in the project are displayed in the right half of the project window when you select the project icon.



Click in the left half of the window on the boxes containing a plus sign to display the full tree structure of the project and mark the Bausteine folder of PLC_1 or PLC_2. You will get a general overview of the software structure and see all blocks used in this project.



Layout and line compartments For software organization the assembly line is divided into 4 sections:

Magazine and Sorting Units (Symbol = MT)

Handling Unit 1 (Symbol = H1)

Press Unit (Symbol = PR)

Storage and Retrieval ASRS (Symbol = SR) These sections are used as neat and useful arrangement in many parts of the data structure and program administration. The sequence of these sections follows the flow of workpieces moving through the assembly line.

Software structure The software is structured for both PLCs in 10 basic groups:

Program organization FC01H

Inputs FC10H

Alarms FC20H

Common functions FC30H

Manual mode FC40H

Automatic mode FC50H

Device control FC60H

Communication FC70H

Human machine interface FC80H

Outputs FC90H It is referring to the assembly line sections by 4 step sequences: PLC 1:

Magazine and testing FC101H PLC 2:

Handling unit FC131H

Press FC161H

ASRS FC191H Beyond that, the programme contains operating blocks with basic PLC functionality and several data blocks.



Operating block OB1 The operating block OB1 represents the main sweep cycle of the PLC programme. All other function blocks must be called directly or indirectly from the OB1 main program. In this application the first block for each basic group is called in OB1. All other function blocks are called afterwards.

Operating block OB100 The operating block OB100 is used as PLC start up procedure and processed only during the first cycle every time the PLC is started. It contains all necessary operations to clear certain memory bits and set data block values to start up conditions.

Data block DB1 DB 1 contains all actual values used in the programme like:

Current operating mode

Current step numbers for step sequences

Actual positions and current position setpoints

Actual PLC cycle counter

Actual support values for alarm processing

Actual values for ASRS handling

Data block DB4 DB4 contains adjustable machine parameters like:

Machine status bits

Delay times

Positions for handling unit

Parameter for ASRS These parameters can be edited at the HMI parameter screen.



Data block DB8 Data block DB8 is used as interface between the PLC program and the human machine interface TP177B. It contains all necessary common signals and values for communication between PLC and HMI like:

Actual HMI screen number

Alarm bits

Bits for HMI push buttons

Adjustable process values

Status bits and values for visualization

Date and time settings

Data block DB47 DB47 is used as instance DB for reading encoder inputs. This is a system function of the PLC and will be no further explained in this manual. (For more information see CPU manual)

Basic group Program organization FC01G The function blocks FC1 and FC2 are used to implement common functionality, which can be utilized in other parts of the PLC program as supportive features such as

Impulse flags (Memory bits which are TRUE for only one PLC cycle per time unit)

PLC cycle counter

Common timer

Basic group Inputs FC10G This group of function blocks is used to read different types of inputs and to transfer these signals and values to memory bits and data words.

Common digital inputs (transfer to memory bits M150.0-M164.4)

Analog inputs (transfer to data words in DB1)

Encoder inputs (transfer to data words in DB1)

Inputs from ASRS rack feeder positions (analyse and transfer to data words in DB1)



For several practical reasons like flexibility and reutilization of function blocks for other applications, it is recommended to use memory bits instead of digital inputs for common functions.

Basic group Alarms FC20G The basic group Alarms contains all functions connected with generating of alarms and alarm processing. In the PLC program alarms are defined as memory bits MW130-MW142. Each memory word contains 16 bits = 16 Alarms and correlates with one of the assembly line sections. All alarms are allocated to 2 categories:

Alarms category 1 will stop automatic execution (MW130)

Alarms category 2 are only displayed indications with some specific effects on related devices (MW132-MW142)

The group starts with FC21 Alarm administration. This function block contains functionality for:

Generating of alarm status bits (M128.0-M128.1)

Monitoring the occurrence of new alarms (M129.0)

Resetting alarms

The alarms are generated in function blocks FC22-FC26 which are also corresponding with the assembly line sections and used as interlock conditions in all following program groups. Usually, alarm bits are set in one of the function blocks FC22-FC28 and must be reset by the operator. The operator uses a push button PB Quit on the main HMI screen which is connected with DB8.DBX60.4. In FC21-NW5 this bit is used to reset all alarm memory bits. In case the alarm condition still exists, the alarm will be set again in FC22-FC28 and therefore active in all following interlocks. A list of all alarm texts can be found in the WinCC application for HMI TP177B. In FC82 HMI Messages, all alarm memory words are transferred to the HMI interface DB8. This is necessary, to switch the sequence of the first and second byte in each word.



Basic group Common functions FC30G The Common function blocks contain basic process functionality such as

FC31 Operating Modes

FC32 Program selection

FC33 Workpiece management

FC34 Common status bits The assembly line is controlled by use of 4 operating modes:

1.) No operation 2.) Manual operation 3.) Automatic stop 4.) Automatic running

All conditions and interlocks for operating modes are contained in FC31-NW3. Conditions for operating modes are safety inputs, alarms and operator actions. Several Bits in DB8 (HMI interface) connected with push buttons on the main HMI screen are used for operator input. In FC32 (Program selection) memory bits are set for all available assembly-program versions of the assembly line. Program selections come from the main parameter screen of the HMI using DB8.DBW80 and DB8.DBW82. The workpiece management in FC33 sets and resets memory bits M90.0 H M95.4 for every workpiece moving in one of the 6 sections of the assembly line. This memory bits are used in other parts of the program for device control and workpiece monitoring. In FC34 common status bits are defined for different processing purposes. All status bits are described by memory bit- and network comments. They are used as interlocking conditions in automatic mode, device control and other parts of the program. To understand the purpose and functionality of each status bit, it is recommended to use the reference table for cross references provided by the SIMATIC STEP 7 manager.

Basic group Manual mode FC40G FC40 = Manual operation calls function blocks FC41-FC44 which contain the manual operations for each assembly line section. The function blocks are only active in manual mode.



In order to control devices from different parts of the program in varying operating modes, each device has a specific Device status bit (M70.0-M80.0). In manual mode, these status bits are set in the manual function blocks FC41-FC46 by connecting the bits with HMI interface bits from push buttons displayed on the manual HMI screens.

Basic group Automatic mode FC50G Automatic mode can be divided into operating mode Automatic stop and operating mode Automatic running. In Automatic stop all devices and units of the assembly line are stopped and ready for the operator to push the Start button (DB8.DBX60.2) at the main HMI screen. In Automatic running all devices of the assembly line are controlled automatically by step sequences and position controllers. In FC50 = Automatic operation, all basic administrative issues for automatic mode are handled:

Resetting step sequence numbers in manual mode

Calling of step controllers in automatic mode

Calling of position controllers

Calling of device function blocks FC51 manages all step controllers. Each section of the assembly line has a specific step sequence. Step controllers work with a step number (DB1.DBW10-20) and st

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modular Mechatronic System "SSC2P2HV2 " USER & SOFTWARE MANUAL

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