Prolog Manual A005

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Prolog-factory

Manual



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

Order-NR.:

Type: Manual prolog-factory

Designation Prolog_Manual_A005.doc

Printed: August 13

Autor: Schober

Graphics: Schober

Layout: Schober

© Festo Didactic GmbH & Co.KG., D-73770 Denkendorf, 2013

Internet: www.festo.com/didactic

e-mail: [email protected]

This manual, all text and illustrations included, is protected by copyright. Any utilization outside the

limits of the copyright law and other than training purposes are not permissible without our definite

approval. This applies in particular to reproductions, operations, translations, micro filming and the

storing and processing into electronic systems. Parts of this manual may be copied by the authorized

user, exclusively for teaching purposes. Distribution of this documentation, as well as reproduction,

use and spread of its contents is prohibited, insofar not permitted explicitly. Offences are liable to

compensation. All rights reserved, especially the right to execute registrations concerning patents,

designs for use and patterns.

http://www.festo.com/didactic



mailto:[email protected]







© Festo Didactic GmbH & Co.KG. • prolog-factory 3

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

This installation was developed and manufactured only for use in basic and further

training in the fields of automation and communications. The training company

and/or the training staff must ensure that the trainees observe the safety

precautions described in the accompanying manuals.

Furthermore this manual describes setup and possible uses of the singular stations.

It contains all information and data required for commissioning, maintenance and

operation.

Festo Didactic accepts no liability for injury or harm to trainees, the training

company and/or any third parties occurring when the installation is used for any

purpose apart from training, except Festo Didactic has caused such injury or harm

intentionally or by grossly negligence.

The manual is divided into four parts:

Part A

In addition to technical data, Part A contains an overview of the possible uses of

the stations.

Part B

Part B contains some exercises and the solutions for this exercise (Not available

for each station).

Part C

Part C contains the pneumatic and electrical diagrams for the station and the

listing of the control programs (Not available for each station).

Part D

Part D contains data sheets and technical information about the electrical and

electronic modules used.

1 Intended use




The list below provides an overview of the most important standards and

regulations relating to mechanical, electrical and safety-engineering design and

production.

DIN EN 292 -Machine safety

DIN EN 60204 - Electrical equipment of industrial machines

DIN VDE 0113 - See DIN EN 60204

DIN 40719 - Circuit documentation

VDI 2853 - Technical safety requirements concerning the building, equipping and

operation of industrial robots

VDI 2853 - Technical safety requirements concerning automated production systems

VDI 2411 - Terms and explanations in conveying and handling

VDI 2860 - Assembly and robotics - terms

VDI 2861 - Assembly and robotics - characteristic quantities

DIN 19245 - PROFIBUS Part 1-3

As far as possible, the System is maintenance-free. All bearings are lubricated for

life. The installation was designed in such a way as to keep the number of wearing

parts to a minimum. This does not include machines that are part of optional

expansions (such as industrial robots).

At this point we would like to point out that this manual and the concept of the

operating instructions for a Flexible Training System of this type are regularly

updated. To ensure that the instructions are ever more user-friendly, you would help

us a great deal by passing on your suggestions for improvement. Please let us know

of your suggestions, corrections or ideas, either in writing or via telephone:

+49(711-3467-0)

List of applicable standards

and regulations




Contents

1 Intended use _______________________________________________________ 3

2

Introduction ______________________________________________________ 11

2.1

General ______________________________________________________ 11

2.2

Customer system ______________________________________________ 12

2.2.1

Triple stack magazine station ________________________________ 13

2.2.2

Testing station with color sensor _____________________________ 14

2.2.3 Processing station _________________________________________ 15

2.2.4

Pick and place station ______________________________________ 16

2.2.5

Fluid muscle station ________________________________________ 17

2.2.6

Storing station ____________________________________________ 18

2.2.7

Separating station _________________________________________ 19

2.2.8 Sorting station ____________________________________________ 20

2.2.9 Commissioning station _____________________________________ 21

2.2.10

Log area__________________________________________________ 22

2.2.11

Robotino 1&2 _____________________________________________ 23

2.3

Didactic structure ______________________________________________ 24

2.4 Duty of the operating authority ___________________________________ 27

2.5 Duty of trainees _______________________________________________ 27

2.6 Warranty and liability ___________________________________________ 28

2.7

Intended use __________________________________________________ 28

2.8

Important notes _______________________________________________ 29



Contents


3

General safety instructions __________________________________________ 31

3.1

Handling the system____________________________________________ 31

3.1.1

Dangers in handling the machine _____________________________ 31

3.1.2

Safety precautions in standard operation ______________________ 32

3.1.3 Dangers due to electric current _______________________________ 32

3.1.4 Dangers due to pneumatic energy ____________________________ 33

3.1.5 Maintenance – Servicing – Malfunction removal _________________ 33

3.1.6

Organizational measures ____________________________________ 33

3.2

Personnel ____________________________________________________ 34

3.2.1

Notes on personnel ________________________________________ 34

3.2.2 Training operations ________________________________________ 34

3.2.3

Outside training operations _________________________________ 34

3.3

Emergency stop system _________________________________________ 34

3.3.1

Safety symbols ____________________________________________ 35

4

Commissioning ____________________________________________________ 37

4.1 Transport _____________________________________________________ 37

4.1.1

Unpacking ________________________________________________ 37

4.1.2

Scope of delivery __________________________________________ 37

4.2

Set up _______________________________________________________ 38

4.2.1

General information ________________________________________ 38

4.3

Commissioning ________________________________________________ 41

4.3.1 Pneumatic commissioning ___________________________________ 41



Contents


4.3.2

Electric commissioning _____________________________________ 41

4.3.3

Connecting communication cables ____________________________ 42

5

Operation ________________________________________________________ 47

5.1

General operation notes ________________________________________ 47

5.1.1 Behaviour rules ___________________________________________ 47

5.1.2 Operation rules ____________________________________________ 47

5.2 Process description ____________________________________________ 48

5.2.1

Material flow ______________________________________________ 49

5.3

Robotino information and operation ______________________________ 51

5.3.1

General __________________________________________________ 52

5.3.2 Start up __________________________________________________ 54

5.3.3

Switch off the robotino _____________________________________ 55

5.4

Program start _________________________________________________ 56

5.6 Program Upload robotino __________________________________________ 57

5.5

Robotino-Pro-Log ______________________________________________ 65

5.5.1 Explanations ______________________________________________ 67

5.5.2

Sequence to collect one Palette ______________________________ 67

5.5.3

Global Variables ___________________________________________ 69

5.6

Data Exchange Variables ________________________________________ 70

5.7

Log area information and operation _______________________________ 71

5.7.1

General __________________________________________________ 71

5.7.2 Start up log area ___________________________________________ 73



Contents


5.8

Start up MPS stations __________________________________________ 74

5.8.1

Requirements _____________________________________________ 74

5.8.2

Reset process of MPS-stations _______________________________ 74

5.9

Start up commissioning station __________________________________ 75

5.9.1 Requirements _____________________________________________ 75

5.9.2 Reset process robot station _________________________________ 75

5.10 Default mode _________________________________________________ 76

5.11

MES Mode ____________________________________________________ 78

6

WINCC ___________________________________________________________ 79

6.1

System information ____________________________________________ 79

6.1.1 Start-up WINCC ____________________________________________ 79

6.2

Use Runtime Application ________________________________________ 80

7

MES Software _____________________________________________________ 87

7.1.1

Software requirements _____________________________________ 87

7.2

Settings ______________________________________________________ 88

7.3 Operation ____________________________________________________ 90

7.4

Create a new order ____________________________________________ 103

7.4.1

Reference guide to create a new order ________________________ 103

7.5

Workaround Error on Storage Station ____________________________ 105

8

Process description _______________________________________________ 107

8.1

Distributing Station ___________________________________________ 107

8.1.1 Standalone mode of Distributing Station ______________________ 107



Contents


8.1.2

MES mode of Distributing Station ___________________________ 108

8.2

Testing Station _______________________________________________ 110

8.2.1

Standalone mode of Testing Station _________________________ 110

8.2.2

MES mode of Testing Station _______________________________ 112

8.3 Processing Station ____________________________________________ 114

8.3.1 Standalone mode of Processing Station ______________________ 114

8.4 Pick & Place Station ___________________________________________ 116

8.4.1

Standalone mode of Pick & Place Station _____________________ 116

8.5

Fluidic Muscle Press Station ____________________________________ 118

8.5.1

Standalone mode of Fluidic Muscle Press Station ______________ 118

8.6 Storing Station _______________________________________________ 120

8.6.1

Standalone mode of Storing Station _________________________ 120

8.6.2

MES mode of Storing Station _______________________________ 124

8.7

Separating Station ____________________________________________ 130

8.7.1

Standalone mode of Separating Station ______________________ 130

8.7.2 MES mode of Separating Station ____________________________ 132

8.8

Sorting Station _______________________________________________ 134

8.8.1

Standalone mode of Sorting Station _________________________ 134

8.9

Robot Station and Robotinos ___________________________________ 136

8.9.1

Standalone mode of Robot Station and Robotinos ______________ 136

8.9.2

MES mode of Robot Station ________________________________ 140

8.9.3 MES mode of Robotino 1 ___________________________________ 146



Contents


8.9.4

MES mode of Robotino 2 ___________________________________ 149

9

Technology ______________________________________________________ 151

9.1

drawings ____________________________________________________ 151

9.2

Modules in use _______________________________________________ 152

9.2.1 Pallet ___________________________________________________ 152

9.2.2 Work pieces _____________________________________________ 153

10 Pneumatic _____________________________________________________ 155

10.1

Pneumatic supply _____________________________________________ 155

11

Electrical system ________________________________________________ 157

11.1

Power supply ________________________________________________ 157

11.2 Controller ___________________________________________________ 158

11.3

Wiring ______________________________________________________ 159

11.3.1

I/O-Components __________________________________________ 159




In the development of the system, various production technologies have beencombined into one installation. The aim of the installation is the increase of

competence, from a simple setting of examples up to a complete production

process, including all features.

Additionally, to technical and social competence, the comprehension of the process

and the interaction of the respective components appear in clear presentation.

This manual describes working with the prolog-factory system. Everything is

explained and described for the operation of necessary events. With the help of

graphics or pictures a simple communication should be obtain.

Complete operating instructions which explain the processes of the system are

available for working with the system. Station manuals are also available for the

individual stations.

Festo Didactic succeeded in using the most updated industrial hard- and software

for this model production.

The PRO-LOG Factory consists of 3 main areas:

The Production Line, where the products are producedThe Commissioning Station, where the customer orders are picked

The Warehouse Area, where the customer orders (pallets) are buffered until delivery

The production line itself consists of 8 MPS Stations. Each Station has its own

controller to support a decentralized control structure.

The Commissioning Station consists of a 6 axis robot. The customer orders are

completed according the order data in this station. After completion, the pallets

(orders) are put to the warehouse input slide.

The warehouse is served by mobile robots. The mobile robots receive their transport

orders from the MES according to the warehouse management data.

They move

Empty pallets to the commissioning robot

Completed orders from the warehouse input slide to the high-bay storage

Deliveries from the storage to the warehouse output slides

2 Introduction

2.1

General



Introduction


Overview prolog-factory system

Position Description Position Description

1 Triple stack magazine station 8 Sorting station

2 Testing station with color sensor 9 Robotino 2

3 Processing station 10 Robotino 1

4 Pick and place station 11 Log area

5 Fluid muscle station 12 Commissioning station

6 Storing station 13 Connecting conveyor 3

7 Separating station

2.2 Customer system



Introduction


2.2.1 Triple stack magazine station

Triple stack magazine station

The triple stack magazine station separates workpieces from 3 magazines. Up to

eight workpieces are stored in each of the magazine tubes of the stacking

magazines. A double-acting cylinder pushes the workpieces out one at a time

directly to the transfer point of the downstream station.



Introduction


2.2.2 Testing station with color sensor

Testing station with color sensor

The Testing station detects the various properties of the work pieces inserted into it.

It differentiates work pieces with the aid of an laser distance sensor and a color

sensor. A retro-reflective sensor monitors whether the operating space is free before

the work piece is measured for height. An analogue sensor measures the height of

the work piece. At the same time a color sensor is checking out the color of the work

piece. The parts are guided on the conveyor to the neighboring station. Faulty work

pieces are rejected via a slide.



Introduction


2.2.3 Processing station

Processing station

In the Processing station, work pieces are tested and processed on a rotary indexing

table. This station only uses electrical drives. The rotary indexing table is driven by a

DC motor. The table is positioned by a relay circuit, with the position of the table

being detected by an inductive sensor. On the rotary indexing table, the work pieces

are tested and drilled in two parallel processes. A solenoid probe with an inductive

sensor checks that the work pieces are inserted in the correct position. During

drilling, the work piece is clamped by a solenoid actuator. Finished work pieces arepassed on via the electrical sorting gate.



Introduction


2.2.4 Pick and place station

Pick and place station

The Pick and Place station is equipped with a two-axis Pick and Place module. Work

piece housings placed on the conveyor are detected by an optical diffuse sensor.

The work piece is transported to the pneumatic separator on the conveyor and

detected by a second diffuse sensor. The Pick and Place module picks up a work

piece insert from the slide and places it on the work piece housing. The complete

work piece (housing and insert) is released by the separator and transported to the

end of the conveyor. A light barrier detects the work piece at the end of the

conveyor.

This station can also be used to perform the following tasks:

Rejection of work pieces (housing or basic body) on the slide

Alternative feeding of work pieces (housing or basic body) from the slide



Introduction


2.2.5 Fluid muscle station

Fluid muscle station

The Fluidic Muscle Press station presses work piece inserts into the housings. The

rotary/linear actuator (transfer device) moves the housing with the insert placed on

it under the press. The pneumatic muscle performs the pressing operation. The

finished work piece is then transported to the transfer position using the

rotary/linear actuator. An optical diffuse sensor is attached to the arm of the

actuator for sensing the work piece. The pressing pressure is monitored and

displayed using the analogue pressure sensor. The press-in speed and depth can be

varied both manually – via throttle and pressure regulator – and electronically – via

the proportional pressure regulator.



Introduction


2.2.6 Storing station

Storing station

The Storing station places work pieces in, and takes work pieces out of storage. The

station is equipped with three storage levels, with a level each for six red, six silver

and six black work pieces. The work pieces are gripped using a pneumatic gripper.

The linear movement is executed using a linear cylinder. The rotary movement is

performed by an electrical servo drive with integrated controller. The stroke

movement is executed using an electrical linear axis with separate controller.

During placement into storage, a work piece inserted in the Holder module is

detected using the color sensor. The work piece is placed in the next free

compartment in the corresponding storage level based on the color. Upon removal

from storage, the work pieces are transported from the shelf compartments to the

downstream station.

The Storing station can be employed as the first station or the last station in an

MPS® combination.



Introduction


2.2.7 Separating station

Separating station

The Separating station differentiates work pieces based on their color and material

with an inductive and an optical sensor. It separates them into two different materialflow directions.

In default mode the red workpiece are transported to the end of conveyor, the black

and silver are transported to the rear. In MES mode the workpiece is transported to

the rear, if it is matching with the order (If not, transported to the end of conveyor).

Fibre-optic through beam sensors with optical sensors monitor the material flow on

the conveyors.

The Separating station can be supplemented with MPS® downstream stations in

two directions.



Introduction


2.2.8 Sorting station

Sorting station

The Sorting station sorts work pieces onto three slides. Work pieces placed on the

start of the conveyor are detected by a diffuse sensor. Sensors upstream of the

stopper detect the work piece features (black, red, metal). Sorting gates actuated by

short-stroke cylinders via a deflector allow sorting of work pieces onto the

appropriate slides. A retro-reflective sensor monitors the level of the slides.



Introduction


2.2.9 Commissioning station

Commissioning station

The commissioning station commissions work pieces from a conveyor on pallets.

Empty pallets are moved from the input slide to the buffer positions on the station.

The commissioned pallets are moved to the output slide for further use. The

complete handling of pallets and work pieces is done be the robot.



Introduction


2.2.10 Log area

Log area

The log area is a logistic field of 2x2m. The high bay racking is used to buffer up to 6

pallets. There are 3 slides for the output of the pallets. Each of these slides is

equipped with a RFID Sensor. A further slide for the input of empty pallets is

available.

The slides to the commissioning station are to supply the commissioning station

with empty pallets and to take the equipped pallets from.

2 robotinos are responsible for the handling of the pallets.



Introduction


2.2.11 Robotino 1&2

Robotino

The 2 robotinos are equipped with a lifting system to lift and lay down the pallets

from and to the slides.

The task of the first robotino is to move the pallets from the output slide of thecommissioning station to the high bay racking and to pick up the emtpy pallets from

the input slide of the log area and move them to the input slide of the

commissioning station.

The task of the second robotino is to move the pallets from the high bay racking to

the 3 outputs slides from the log area.



Introduction


The installation is structured, to enable methodical learning, i.e. from single use of

modules to the complex and complete installation. Perhaps even in combination

with further systems.

For example, it is possible to pick out a single module to start with the first steps,

e.g. the robot.

First the mechanical assembly is considered. The robot’s radius of action requires

integration into the location of the robot.

The following step could be the connection of all cables required for operation and

the set-up of the robot.

Moving the robot and teaching the required positions are the first real operations

with the robot, which introduces the user how to deal with the teach-box.

The robot’s programming can be started, as soon as the robot can be moved by the

teach-box. Small programs, which can be created by using the CIROS/Cosirop

software, are expandable for the complex programs.

Orders to further stations and from other controls can be installed in the programs.

Once the learning process of this module has been concluded, these learning stepscan be transferred to the next module. As soon as all of the modules have been

processed individually, the modules can be interconnected and the programs can be

adapted. A complete production process can be simulated.

This is an ideal training area for the professional practice of mechatronics, as well as

all of the technical ranges (mechanical, electrical and pneumatic processes) are

represented in a simple and clearly way, concerning each one of the modules and

the complete system.

2.3 Didactic structure



Introduction


The installation permits to face students to the reality of manufacturing processes

by allowing them to apply individual technologies already taught in the preliminary

phases of engineering studies. Thus, each technology is considered first separately

and then combined together to optimize the manufacturing processes.

Training contents covering the following subjects can be taught:

Mechanic:

Adjusting of a handling system

Assembly of singular station

Using mechanical interfaces

Electronic:

Wiring and testing electrical components

Reading and designing electrical circuit diagrams

Getting familiar with electrical drives

Working with electrical interfaces

Robotic:

Use of industrial robots

Fundamentals of robot technology

Robot programming

Sensoric:

Using limit switches and sensors

Getting to know different types of sensors (inductive, optical, capacitive, analogue)

Pneumatic:

Professional tubing of pneumatic components according to circuit diagrams

Getting to know and using pneumatic components (different cylinders, valves,

grippers)

Using vacuum technology



Introduction


Ident system:

Getting familiar with the Identification system

Data processing via Ident and PLC

PLC:

Getting to know the structure and mode of operation of a PLC

Programming a PLC in different PLC languages

Interfacing a PLC to a Robot Controller and a visualization system

Getting to know special function modules for positioning, counting

Maintenance and Troubleshooting:

Locating and rectifying faults and malfunctions

Optimizing automated systems

Commissioning:

Adjusting mechanical and electrical componentsAdjusting sensors and limit switches in automated systems

Commissioning systems by means of a PLC



Introduction


The operating authority undertakes to ensure that the system is used only by

persons who:

are familiar with the basic regulations regarding operational safety and accident

prevention and who have received instructions in the handling of the system.

have read and understood the chapter on safety and the cautionary notes in this

manual.

Safety-conscious working of the persons should be regularly vetted.

Prior to commencing work, all persons assigned to working on the system have a

duty to:

read the chapter on safety and the cautionary notes in this manual and,

observe the basic regulations regarding operational safety and the prevention of

accidents.

2.4 Duty of the operating

authority

2.5 Duty of trainees



Introduction


In principle all our „Terms and Conditions of Sale“ apply. These are available to the

operating authority upon conclusion of the contract at the latest. Warranty and

liability claims for persons or material damage are excluded if these can be traced

back to one or several of the following causes:

Use of the system not in accordance with its intended purpose

Incorrect assembly, commissioning, operation and maintenance of the system

Operation of the system using faulty safety equipment or incorrectly fitted or non

operational safety or protective devices

Non observance of notes in the manual regarding transport, storage, assembly,

commissioning, operation, maintenance and setting up of the system

Unlawful constructional modifications on the system

Inadequate monitoring of components subject to wear

Incorrectly carried out repairs

Catastrophes as a result of foreign bodies and vis major.

Festo Didactic herewith rules out any liability for damage or injury to trainees, the

training company and/or other third parties which may occur during the

use/operation of the system other than purely in a training situation, unless suchdamage has been caused intentionally or due to gross negligence by Festo Didactic.

This installation was developed and manufactured only for use in basic and further

training in the fields of automation and communications. The training company

and/or the training staff must ensure that the trainees observe the safety

precautions described in the accompanying manuals.

Furthermore this manual describes setup and possible uses of the singular stations.

It contains all information and data required for commissioning, maintenance and

operation.

Festo Didactic accepts no liability for injury or harm to trainees, the training

company and/or any third parties occurring when the installation is used for any

purpose apart from training, except Festo Didactic has caused such injury or harm

intentionally or by grossly negligence.

The use of the system for its intended purpose also includes:

Following all advice in the manual and

Carrying out inspection and maintenance work.

2.6 Warranty and

liability

2.7 Intended use



Introduction


The basic requirement for safe use and trouble-free operation of the system is to

observe the fundamental safety recommendations and regulations.

This manual contains important notes concerning the safe operation of the system.

The safety recommendations in particular must be observed by anyone working on

the system.

Furthermore, the rules and regulations for the prevention of accidents applicable to

the place of use must be observed.

2.8 Important notes



Introduction





3.1.1 Dangers in handling the machine

The installation has been constructed technologically up to date and in conformance

with the recognized rules of safety engineering. Nevertheless, during operation it is

possible that harm might be caused to the user or third parties or that the

installation or other property might get damaged. Therefore, the installation has to

be handled according to specified operational use in perfect technical condition

only.

Safety endangering malfunctions cannot be tolerated during training and have to be

removed immediately.

The system is to be used only:

for its intended purpose and

in absolutely safe conditions.

Faults impairing safety must be rectified immediately!

3 General safety instructions

3.1 Handling the system



General safety instructions


3.1.2 Safety precautions in standard operation

Put the installation into operation only, once all of the protection settings are

completely functional.

At least, before starting operation, check the installation for externally visible

damages and for the reliability of the safety devices.

Do not grip into the installation while in operation.

Before circuit construction, circuit disassembly and circuit modification: switch off

air pressure and power supply.

General safety regulations are to be observed: DIN 58126 and VDE 0100.

3.1.3 Dangers due to electric current

As soon as maintenance is completed, check the function reliability of the safetydevices.

Only trained experts in electric or electronic engineering are permitted to carry out

work on the electric supply system.

The terminal boxes are to be kept closed at all times. Access must be permitted only

under supervision of a member of the training staff.

Do not activate electric limit switches manually during fault search. Tools are to be

used.

Only low voltage 24VDC is to be used.





3.1.4 Dangers due to pneumatic energy

Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt

air pressure supply immediately.

Caution! When the air pressure supply is activated, cylinders may move in or out.

Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In

this case, keep on holding the end of the tube.

Do not exceed the permitted operating pressure. See data sheets.

3.1.5 Maintenance – Servicing – Malfunction removal

Carry out adjustments and inspections as instructed, in accordance with the

specified intervals.

Secure the compressed air and electricity supplies to prevent unintentional start-up.

During inspections, maintenance and repair work, the machine must be de-energized, de-pressurized and secured against unexpected restart.

All screw connections released during maintenance, inspection or repair work must

be checked to ensure correct re-tightening.

3.1.6 Organizational measures

All existing safety devices must be checked at regular intervals.





3.2.1 Notes on personnel

Basically two situations have to be considered, concerning matters on personnel.

Activities during training operations

Activities outside training operations

3.2.2

Training operations

Trainees are permitted to work with the machine only under strict supervision of an

experienced person or an instructor.

Activities of trouble-shooting and fault correction are to be checked by the

instructor. Special care should be taken regarding safety aspects.

3.2.3 Outside training operations

Activities in the areas of maintenance, service and repair are to be carried out by

only persons with appropriate technical qualifications.

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

3.2 Personnel

3.3

Emergency stop

system





3.3.1 Safety symbols

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

This symbol indicates an immediate

threat to a person’s health or life.

DANGER !

Failure to pay attention to this symbol may result in serious health damage, which

may even lead to life-threatening injuries.

This symbol emphasizes important

information for correct machine

handling.

IMPORTANT

Failure to pay attention to this symbol may result in damages to the machine or to

its surroundings.

This symbol indicates operational tips

and especially useful directions. i INFORMATION

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








Care is to be taken that the transport of the stations is to be executed only by asuitable transport vehicle. The weight amounts up to 500 kg, depending on the

station.

The route of transport is to be cleared in advance, to be accessible to the transport

vehicle. Installation of warning signs or barriers may be required.

The transport boxes are to be opened with care, as additional components, such as

computers may be contained in the delivery, which are to be protected from falling

out.

Once the transport box has been opened and the possibly contained additional

components removed, the station can be taken out to be transported to its

destination by means of two fork-lifts or one fork-lift truck.

Please check the stability of all of the profile connectors by means of an Allen key

size 6. The connectors may have come loose during transport, due to inevitable

vibration.

Pay special attention to all overhanging components. Sensors and similar small

parts are very easily damaged in case of improper transport.

The stations are not to be picked up by or even under the mounted feet – increased

risk of becoming trapped or contused.

Check the station for any possible damaged once unpacked. The carrier and Festo

Didactic are to be notified immediately of any damage.

4.1.1 Unpacking

Carefully remove the padding material in the container box when unpacking the

station. When unpacking the station, make sure that none of the station assemblies

have been damaged.

Check the station for any possible damaged once unpacked. The carrier and Festo

Didactic are to be notified immediately of any damage.

4.1.2

Scope of delivery

Check the scope of delivery against the delivery note and the order. Festo Didactic

must be notified immediately of any discrepancies.

4 Commissioning

4.1

Transport

i



Commissioning


4.2.1 General information

The installation is to be set up in a frost-free room with maximum relative air

humidity of 70%.

In countries with an atmospheric humidity over 70% and temperatures above 25

degrees Celsius are the premises to provide an air-conditioning system for constant

surroundings conditions.

To comply with the regulatory guidelines, sources of electrical interference such as

welding plants, large motors and contactors are to be checked for electromagnetic

compatibility in advance and screened where necessary.

To ensure fault-free operation a load-bearing floor is required to avoid settling.

Allow sufficient distance between the installation and the wall of the room.

Any dust originating from construction work has to be kept off the installation (by

covering).

The log area is the first station of whole system which is built up. For the set-up of

the system follow the instructions below:

At first the room has to be measured, if not done so previously. The measures of all

stations has to be marked roughly onto the floor space (i.e. with adhesive tape) to

avoid shifting at a later stage.

The station is placed in its final position, before it is balanced, by means of a spirit-

level. The table from the log area should be at a height of 785 mm.

4.2 Set up



Commissioning


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

Installation design prolog factory



Commissioning


Dimension drawing



Commissioning


Commissioning of the system can ensue only, once all of the stations are connected

to their definite position.

4.3.1 Pneumatic commissioning

The mechanical construction must be finished. At the beginning the stations have to

be attached to the pneumatic system of the room. In most cases the maintenance

unit is on the profile plate of the station. The coupling has a 5 mm nominal diameter.

If the available system is equipped with 7.9 mm nominal diameter, it is possible to

change the coupling of the maintenance unit with a greater one. (reducer 1/8 on 1/4

necessary).

If this has been carried out, the stations can be provided with 600 kPA/6 bar and the

pneumatic commissioning is realized.

4.3.2 Electric commissioning

The stations must be provided with electrical voltage now.

The stations are provided with a power supply unit which is provided with a voltage

of 110/230 V. The delivered cables have a completely protected norm plug, thismust be plugged into an electrical socket protected sufficiently. Distribution strips

are, enclosed to this also for the connection of other stations. If an extension for the

cable is necessary for the distribution strip, this can to be executed only by a trained

expert. The electrical socket must be protected, corresponding to the customer.

The power supply (24 VDC) of the sensoric and the actuators of the station is

provided in each case by means of a 2-pin cable. The voltage supply is a 24 V power

supply unit, contained in the control cabinet or somewhere in the station.

To avoid problems during the operational process, individual protection (16A) of the

installation is recommended.

4.3 Commissioning



Commissioning


4.3.3 Connecting communication cables

The PRO-LOG Factory covers all state of the art industrial communication levels and

control technologies.

The control levels are:

Factory level: Order Entry

Plant level: SCADA

Device level: PLC, RC

The communication systems are:

Ethernet (LAN/WLAN) for communication between PLC and PC (see also

following graphic)

RFID for communication between external I/O parts and PLC (see also

following graphic)

Profibus for communication between Siemens PLC and Turck IO extension



Commissioning


The communication inside the system takes place via Ethernet and Profibus DP. All

connections are pluggable, the exception is the cable from the Drive unit, the cable

is fixed in the drive unit and not pluggable.

Ethernet communication cables



Commissioning


Position Station Ethernet address

1 MES PC 192.168.10.50

2 WinCC 192.168.10.51

3 Triple stack magazine station 192.168.10.1

4 LAN-switch

5 WLan router 192.168.101.2

6 Testing station with color sensor 192.168.10.2

7 Processing station 192.168.10.3

8 Pick and place station 192.168.10.4

9 Fluid muscle station 192.168.10.5

10 Storing station 192.168.10.6

11 Separating station 192.168.10.7

12 Sorting station 192.168.10.8

13 Commissioning station 192.168.10.20

14 Robotino 1 192.168.10.101

15 Robotino 2 192.168.10.102



Commissioning


Profibus communication cables

Position Station Profibus DP address

1 Turk CPU commissioning station DP # 3

2 Drive unit roboter DP # 10

3 PLC commissioning station DP # 2

4 Turk connecting unit log area DP # 5



Commissioning


RFID communication cables

Position Station name

1 RFID sensor robot 1C1

2 RFID Card 1 for RFID sensor robot and slide 1 1K2

3 RFID Card 2 for RFID sensor slide 2 and slide 3 1K3

4 RFID sensor slide 1 1C2






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

The stations require some rules of operation which should be observed. If they are

not complied, faults in the processes are possible. Dangers for the physical health

also cannot be excluded.

It is recommended to observe the following rules strictly.

5.1.1 Behaviour rules

During the operation of the stations it is forbidden to grip in by hand.

With larger audience a mechanical protection of the stations is necessary.

Removing any cable under tension is forbidden.

Water has to be kept away from the plant.

5.1.2 Operation rules

The stations only may be used by introduced persons.

The operation has to be carried out according to the operating instructions.

A pushing the different switches/push buttons of all control units unchecked has to

be stopped.No work piece carriers may be taken by the system.

5 Operation

5.1 General operation

notes



Operation


Orders are entered and started in MES software.

The commissioning station has to equip a pallet like defined in the order. It is

possible to equip the pallet with 1-4 different work pieces.

The commissioning station requests the necessary work pieces at the separating

and testing station. The separating station gets the work pieces from the Storing

station and the testing station gets the work pieces from the distribution station.

There the work piece is checked for height and the color – the color must fit to the

respective order, otherwise the work piece is sorted out on the slide.

If the pallet is equipped, the robot takes the pallet and places it down at the outlay

slide from the station. Robotino 1 takes the pallet from the slide and moves it to the

high bay racking for temporary storage. From there robotino 2 moves the pallet to

the respective outlay slide (Slide 1-3) of the system. The requirement therefore is

that the slides are not occupied – in case the slides are occupied, it is necessary to

put out the pallets by hand. The RFID sensors announce this in MES software, there

the orders are deleted.

5.2 Process description



Operation


5.2.1 Material flow

The processes and the material flow in PRO-LOG Factory is an image of a real

production and distributing enterprise. There are buffers and magazines for the raw

materials, and a storage for the single products. According to the customer orders,

the products are transported JIS (just in sequence) to the commissioning robot. The

pallets are stored in a high bay storage.

The mobile robots are equipped with a fork on a telescope arm and work as a fork

lift to reach the upper positions of the high-bay racking.

Position Material flow Station

1 Work pieces from MPS-System MPS Stations

2 Equipped pallets to high bay storage Robotino 1

3 Equipped pallets to outlay slides 1-3 Robotino 2

4 Empty pallets Robotino 1

5 Sort out work pieces Sorting Station



Operation


Position numbers Robotino / orientation of pallets

Position Position number robotino

1 High bay rack position 1






7 Commissioning station output slide position 7

8 Commissioning station input slide position 8

9 Log area input slide position 9 / Init position robotino 1

10 Log area output slide 3 position 10



13 Init position robotino 2

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

the orientation of the pallet.



Operation


Operation display robotino

Position Function Position Function

1 Display line 1 6 Power button

2 Display line 2 7 Move upwards in menu

3 Display line 3 8 Enter Button

4 Display line 4 9 Move downwards in menu

5 Powers supply light 10 Move back on layer in menu

5.3 Robotino information

and operation



Operation


5.3.1 General

The example is written for robotino 1, the operation of robotino 2 is equal.

If there is no operation at the panel during start up the robotino, the display is going

to stand by mode, press the Return button to bring back the panel to operation.

If the charge of the accumulator is not more than 50% it is possible that the robotino

doesn’t work exactly – in this case or in case of a crash press any button to stop the

robotino.

The external AP switch has following modes

Left position = AP mode

right position = Client mode

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

at the robotino.



Operation


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

robotino.

CF Card slot



Operation


5.3.2 Start up

To start up the robotino, follow the instructions:

1.

Press Power button for more than 2 seconds. The power supply light is starting

to lighten and the digits of the display are active. The controller is booting – wait

till the display shows the robotinos name, the IP address and the accumulator

charge condition.

2.

The accumulator of the robotino has to be loaded more than 50%. Load up the

accumulators with help of the recharger cable for 2-3 hours. See (Line 4 in

display)

3.

If not happened disconnect the charge cable from the robotino.

4.

Press the ENTER button and the system is coming to the main menu.

5.

Press the Arrow down Button to choose the line with the programs and press

the ENTER button.

6.

Choose program

->Prolog_Vx.x_R1.rvw1 (for robotino 1)

->Prolog_Vx.x_R2.rvw2 (for robotino2)

if the program is not available see chapter Download a program to robotino

7.

Be sure that the robotino is at the right starting position (See following picture – the lift has to stand like shown in the graphic – arrow announce direction) pay

attention for the mark on the table.

Pos Function

1

Start

position

robotino 1

2

Start

position

robotino 2



Operation


8.

Press ENTER button

9.

Robotino makes the reference move. After reference move the robot is in start

position and is waiting for orders.

5.3.3 Switch off the robotino

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

supply light expires.



Operation


For both robotinos:

1.

In the display-screen

If the light is not active, press enter

Press enter, you will be in the main menu

With the buttons, you have to go in the menu “programs”

Here, you will see one of the both programs :

ProLog_V1.1_R1

ProLog_V1.1_R2

R1 is the robot with the start-position 9.

R2 is the robot with the start-position 13.

Position the robotino left-handed to the right position

Start the program with enter

5.4 Program start



Operation


The steps to upload the robotino’s program is the same for both robotinos. Make

sure to download the right program:

Robotino 1: Startposition 9, IP address 192.168.10.101

Robotino 2: Startposition 13, IP address 192.168.10.102

Open the following program for robotino 1

Or for robotino 2

5.6 Program Upload

robotino



Operation


In RobotinoView 2 select the tab Main program

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

Robotino 1 -> Value 101

Robotino 2 -> Value 102



Operation


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

window

Double click on UPD connection PLC control.

This opens a new window with the UDP connection settings. The IP address should

be the same as the main plc. The ports are different for the two robotinos:



Operation


Enter port 9180 for robotino 1: Enter port 9181 for robotino 2:



Operation


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

robotino



Operation


The FTP client within RobotinoView opens and connects to Robotino. The IP address

of the Robotino is entered in both IP address fields.



Operation


If successfully connected, the Robotino directories are displayed. Open the

programs directory with a double click.



Operation


Click on Upload current project to upload the opened program

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



Operation


Subprograms

Name Description

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

via OPC.

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

true.

SetPosN Set the global Variable pos_target_x, pos_target_y, and pos_target_phi, to posN_x,

posN_y and posN_phi.

FindLine Search the metal-line and set the global variable lineFound to true, when the Line is

found. ( only with inductive sensors)

InitOdo Save the orientation.

FindStop Search the black band before the docking-position.

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

CopyJob1 Save the order of the PLC.

CopyJob Update the status of robotino via UDP

SetForkN Set the global Variable fork_targetPosition to fork_posN_1 or Fork_posN_2.

LeaveDock Leave the docking-position.

Drive Drive to the Target-position defined with the global variables pos_target_x,

pos_target_y, and pos_target_phi.

Positioning

Fork

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

FindLine-Odo Search the metal-line and set the global variable lineFound to true, when the Line is

found. (with the inductive sensor in the middle of the Robotino and with the

odometry)

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

via UDP.

5.5 Robotino-Pro-Log



Operation


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



Operation


5.5.1 Explanations

Wait the connection.

Initialize the fork. (fork is down)

Save the target position.

Find the metallic line. (only with inductive sensors)

Save the orientation.

Find the black band.

Save the coordinate of the start-position.

5.5.2 Sequence to collect one Palette

1.

Wait for a job and save this job.

2.

Save the right parameters: save the target-position for the Robotino and the

fork.

3.

If the Robotino is already in the source-position:

The fork drives to the position fork_posN_1. (N=number of the source)

4.

If the Robotino is not already in the source-position then its drives to thisposition:

The Robotino leaves the dock.

In the same time, the Robotino drives to the target-position and do the

following sequence:

Initialize the fork.

Save the origin of the fork.

The fork drives to the position fork_posN_1. (N=number of the

source)

The Robotino finds the metallic line. (with inductive sensor and odometry)

The Robotino finds the black band. (with optical sensor)

5.

Save the right parameters: save the right coordinates in the Odometry and save

the next target-position for the fork.

6.

The fork drives to the position fork_posN_2. That means the Robotino takes the

palette in the source.

7.


8.

Save the right parameters: save the target-position for the Robotino and the

fork.

Initialization



Operation


9.

The Robotino drives to the sink-position:

In the same time, the Robotino drives to the target-position and do the

following sequence:

Initialize the fork.

Save the origin of the fork.

The fork drives to the position fork_posN_2. (N=Number of the

sink)

The Robotino finds the metallic line. (with inductive sensor and odometry)

The Robotino finds the black band. (with optical sensor)

10.

Save the right parameters: save the right coordinates in the Odometry and save

the next target-position for the fork.

11.

The fork drives to the position fork_posN_1. That means the Robotino gives the

palette in the sink.

12.

If the Robotino is not in the storage warehouse (position-number between 1 and

6) then the sequence is finished.

13.

If the Robotino is in the storage warehouse (position-number between 1 and 6)

then the Robotino must drive to the start-position:


Save the right parameters: save the target-position for the Robotino.

In the same time, the Robotino drives to the target-position and initialize thefork.

The Robotino finds the metallic line (with inductive sensor and odometry).

The Robotino finds the black band (with optical sensor).

Save the coordinate of the start-position.



Operation


5.5.3 Global Variables

Name Description

Batterie Value of the Batteries in Volt.

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

Robotino The Robotino´s number

101: starting position is pos09_1

102: starting position is pos13_1

dockLeft True, when the dock is left.

fork_posN_1 Position of the fork in the position N.

Fork_posN_2 Position of the fork in the position N.

Fork_posN_2 is always upside of fork_posN_1.

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

fork_targetPosition The fork´s target-position.

gesamt Intermediate variable in the calculation of the PI-controller in the subprogram

FindStop.

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

line.

udp_job_running True, when the Robotino works about an order.

False, when the Robotino is waiting an order.

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

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

posX_1_x

posX_1_y

posX_1_phi

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

The position X_1 precedes the position X: the Robotino go first in the position

X_1 and search the metal-line from this position.

posX_x

posX_y

posX_phi

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

When the Robotino is docked, the odometry save the coordinate of the

position X.



Operation


Name Description

pos_reached True, when the Robotino is on the position pos_target_x, pos_target_y, and

pos_target_phi of subprogram Drive.

pos_target_x

pos_target_y

pos_target_phi

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

rearSensorHitLine This variable is in the subprogram FindLine.

It saves, if the inductive sensor has already once detected the metal-line or not.

stopFound This variable is in the subprogram FindStop.

True, when the Robotino is on the docking-position. That mean, when the optic

sensor has detected the black band.

Name Description

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

job_running True, when the Robotino works about an order.

False, when the Robotino is waiting an order.

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

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

X

Y

Phi

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

system.

These variables are present in the both programs.

5.6

Data Exchange

Variables



Operation


5.7.1 General

Position FunctionPositi

on

Function

1 High bay rack 6 Robotino 2

2 Robotino 1 7 Output slide 1 (order 1)

3 Slide from commissioning station to log area 8 Output slide 2 (order 2)

4 Slide from Log area to commissioning station 9 Output slide 3 (order3)

5 Turk controller board 10 Input slide 1 (empty pallets)

There is no operation system for the log area. The control for the log area is done

from the controller on the turk board. The board is supplied with 24 V from a extern

power supply unit, be sure that the power supply unit is switched on.

The lamps at the slides announce that a order is ready and the pallet is on the slide.

5.7 Log area information

and operation



Operation


The silver help lines on the table are for the Robotino, with a inductive sensor the

Robotino follows the right edge of the line. The black markers are the stopping point

for the Robotino, a optical sensor recognize the marker. The help lines are available

at the slides and at the high bay rack.

Position Function

1 Silver help line (aluminum tape)

2 The robotino orientates at the right edge of the help line

3 Marker to stop the robotino in the right position

4 Direction of robotino to handing over a pallet to a slide



Operation


High bay rack

Position Function







5.7.2 Start up log area

Remove all parts from the outlay slides

Remove all parts from high bay racking

Fill up the Input slide with empty pallets



Operation


The operation of the stations is described in the stations manual – a short cut for

operation to start up the system should be helpful. All stations have the same

procedure.

5.8.1 Requirements

The reset process is the same for each MPS station. Execute the reset process at

each station. The reset process is also to be executed after STOP- or EMERGENCY-

STOP activation.

1. Fill up all magazines

2.

Clear all working positions

5.8.2 Reset process of MPS-stations

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

5.8 Start up MPS

stations



Operation


The operation of the station is described in the stations manual – a short cut for

operation to start up the system should be helpful.

5.9.1 Requirements

Execute the reset process at the robot station. The reset process is also to be

executed after STOP- or EMERGENCY-STOP activation.

1.

Clear all working positions, slides, the high bay rack at the log area and the

pallet reception at commissioning station.

2. Switch on power and air supply

3.

Key switch on Drive Unit to Auto/EXT

Switch Teach Box to disable

Switch on Drive Unit from robot

5.9.2 Reset process robot station

5.9 Start up

commissioning

station



Operation


The default mode is helpful to check the complete system. If the default mode works

without an error, all sensors and actors work faultless. In default mode all stations

starting automatically if the START button at the stations are pressed and all

stations are started without error.

1.

Turn Key switch at all stations to default mode

2. Fill up all magazines at MPS stations

3.

Start all stations with START button

4.

If the start button at the triple stack magazine is pressed, the station is starting

to work. If the following station has now congestion jam, the first workpiece is

separated and transported to the next station. The sequence is starting with a

red workpiece, then a black, then silver and again a red workpiece etc.

5.

The testing station checks the height from the workpiece. If the height is ok., the

workpiece has the right orientation and is transported to the next station. If the

height is not ok. the workpiece is sorted out on the slide

6.

The processing station is processing the workpiece

7.

The pick and place station implements an instrument into the workpiece

8.

The Fluid muscle station is pressing the instrument into the workpiece

9. The storage station moves the red workpieces into the top row, the black

workpieces into the middle and the silver workpieces into the lower row. If thefollowing station is not occupied a workpiece is released from the storage. The

station takes the color with the most workpieces in stock

10.

The sorting station is sorting out the red workpieces to the first slide. The black

and silver workpieces are transported to the commission station

5.10 Default mode

Default mode MPS



Operation


1.

Turn Key switch to default mode

2.

Place empty pallet to input slide at log area

3.

Start commissioning station with START button

4.

The robotino 1 takes the empty pallet from the input slide at log area (robotino

pos. 9) and moves to input slide of the commissioning station (robotino pos. 8)

5.

The robot takes the pallet and moves to pallet reception position 1

6. If a workpiece is available from MPS line, the robot takes the workpiece from the

conveyor. The workpiece is transported to first position on the empty pallet.

7.

If there is another workpiece, this is transported to second position on the

empty pallet. etc.

8. When the pallet is fully equipped, the robot takes to pallet to output slide of the

commissioning station

9.

Robotino 1 is picking up the pallet from commissioning station and moves to the

high bay rack at the log area. There the pallet is stored to shelf 1 of the high bay

rack

10.

Robotino 2 is picking up the pallet from shelf 1 at the high bay rack and moves

to output slide 1 from log area. There the pallet is made available for hand out

of the system.

11. This cycle is continued till all positions are tested once or the default mode is

stopped.12.

In the following the empty pallets from input slide at log area coming to pallet

reception 2 then 3 and 4.

13.

If the first pallet is completely equipped, the workpieces coming to the pallets 2

then 3 and then to pallet 4.

14.

The equipped pallets are coming to high bay rack shelf 2. From there to output

slide 2, from shelf 3 to slide 3 from shelf 4 to slide 1 etc.

Default mode

commissioning



Operation


The MES mode is for automatic mode of the complete system. Operation and order

handling is done by the MES Software.

1.

Turn Key switch at all stations to MES mode (vertical – Auto)

2.

Fill up magazine at distributing stations (MPS)

3.

Prepare storage (MPS) equal the settings in MES

4. Remove all workpieces from storage

5.

Remove all workpieces from working positions

6.

Remove all workpieces from conveyor positions

7.

Remove all workpieces from buffer at Log Area

8. Place empty pallet to input slide at log area

9.

Start all stations with START button

10.

Operation is done by MES Software (See chapter process description)

11.

Announcement is done in WinCC

5.11 MES Mode




The system is extended with a communication layer for using a SCADA system

(Supervision, Control And Data Acquisition) like WinCC, for this system it is called

"Level 2". For data exchange between SCADA system WinCC and the PLCs an

Ethernet network is used.

It is possible to configure the facility; single MPS-stations can be removed or

relocated. If this is done, WinCC can conform to the real system.

6.1.1

Start-up WINCC

Before activating WinCC you have to make sure all programs have been downloaded

to each PLC and all system cable connections are made:

DC24V power supply

6bar system pressure

I/O communication cables according to operation manual

Ethernet cables connecting each PLC and computer

Ethernet cables are connected with the Ethernet switch

Ethernet switch is switched on

Profibus cables connecting PLC commissioning with Turk board

System requirements:

Windows XP with SP2/Vista, English or German Version with Internet Explorer V6.0

Ethernet-card installed to the computer

WinCC V7.0 with SP1 with WinCC-Application

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

6 WINCC

6.1 System information

Notice:




WINCC

Start screen with the overview of the system

Buttons and functions overview

Position Function

1 Choose control panel of station

2 Announcement of chosen station

3 Announcement / operation of chosen control panel

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

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

6 Announcement and choice of station at this position

7 Button to show details of the chosen station

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

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

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

11 Button to announce alarm window

12 Button to announce “shut down WinCC”

6.2 Use Runtime

Application




WINCC

I/O screen.

Buttons and functions I/O´s

Position Function

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

2 Announcement of chosen station

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

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

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

6Choose control panel from station / possible at all fields in control area, it is also possible

to see robotino information

7 Announcement and operation with the chosen control panel

8 Area for control of all stations

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

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

11 Button to the alarm screen

12 Button to shut down WinCC




WINCC

Alarm in I/O´s window

Position Function

1 Announcement of alarm at this station

2 Announcement of alarm somewhere in the system

3 Button to change to alarm window

Alarm class description

ERROR_L0 / fatal error, station doesn’t work anymore, solve problem, quit

Error and reference move necessary

ERROR_L1 / still working and stops at the cycle end, quit error and push

START button

ERROR_L2 / warning, station is still working, if necessary quit error




WINCC

Alarm window warning

Position Function

1 Detailed alarm announcement / background grey for warning

2 Acknowledge and delete all alarms

3 Cancel alarm window without acknowledge the alarm




WINCC

Alarm window / error

Position Function

1 Detailed alarm announcement / background red for error

2 Acknowledge and delete all alarms

3 Cancel alarm window without acknowledge the alarm




WINCC

Shut down menu

Position Function

1

Choose function

- Deactivate WinCC runtime and change to windows / WinCC is still active

- Close project and shutdown WinCC to change to windows

- Restart computer

- Shutdown computer

2 Acknowledge function from shut down menu

3 Cancel shut down menu and change back to WinCC runtime




WINCC

Configuration window

Position Function

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

2 Description of fault

3 Confirm fault




The Manufacturing Execution System software is responsible for the ordermanagement. If the option MES is selected at the control panel, all orders are

executed from this software.

7.1.1 Software requirements

Windows 7 with newest service pack

Microsoft.Net framework V4.0 has to be installed

MES

Pos. Description

1 Start the software with double click on the icon on desktop

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

7 MES Software




MES-Software

At the flag “TOOLS” it is possible to reload the system or to edit the options. If you

choose the options, you can choose between common and communication.

Settings in common options

Here you can adjust the common system, it is possible to

Delete all orders during start up

Delete all buffers during start up

Delete all finished orders during start up

Set communication to active during start up

Create Logfile

edit time to refresh the overview Edit the order standard

7.2 Settings




MES-Software

Settings in communication options

Here you can adjust the communication, it is possible to

Edit the port

Edit the quantity of clients

It is recommended that the user doesn’t change something in these options;

otherwise, the program files have to be adjusted to the new settings.




MES-Software

Start screen MES software

The left side of the window is the order view and the right side is the main view, the

main view is announced in real time.

Pos. Description Pos. Description

1 Change mode (see following screens) 6 Button to delete all orders

2 Change order announcement between list and

tree

7 Button to disable all orders

3 Announcement of order to produce a cylinder

Background white = order not started

Background yellow = order started

Background blue = order ready

Background red = error

8 Announcement of actual order

4 Announcement of order to produce a pallet 9 Announcement of actual order / with click in

field, a new window is opened

5 Announcement of workpiece in suborder

Cylinder in red, black or silver

10 Announcement of actual order in new window

(See screen commissioning order)

7.3 Operation




MES-Software




16 Announcement of actual order in new window,

it is possible to delete orders in the window



17 Announcement of status guilty for all stations

green = online / red =offline



18 New window with right click/See screen

inventory





15 If a pallet is available at a penholder position,

the position is marked green




MES-Software

Overview – orders shown as tree

Overview – orders shown as list




MES-Software


1 Change mode (see following screens) 8 Announcement of actual order / cylinder or

pallet are possible

If the order is a commissioning order it is

possible to choose the order, to define the

output slide and to edit each position

2 Announcement of not enabled orders – with

right click on order it is possible to enable or

delete the chosen order

9 The single positions from the order are

announced here. It is possible to choose and

edit each single position

3 Delete selected order 10 Delete selected position

4 Add new order 11 Cancel all edits

5 Enable all orders 12 Save all edits

6 Delete all orders 13 Add new position

7 Announcement of actual order – it is possible

to edit the start date and the customer

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




MES-Software

Overview – orders shown for commissioning a palette

Overview – orders shown to produce a cylinder




MES-Software

Analysing orders

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

Analysing parts

Announcement of all produced parts.




MES-Software

Configuration – resources

Pos. Description

1 Change mode (see following screens)

2 Choose configuration area

3 Announcement of resources / chosen resource is blue

4 Announcement of functions from the chosen resource

5 Announcement of parameters

6 Picture of resource




MES-Software

Configuration – production orders

Pos. Description



3 Announcement of order / chosen order is blue

4 Select order types:

production (cylinder)

commissioning (feed a pallet)

templates (suborders)

5 Announcement of tasks of the chosen order

6 Announcement of parameters of the chosen task




MES-Software

Configuration – buffers

Pos. Description



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

the active shelf

4 Save actual content

5 Choose resource of buffer

6 Choose buffer

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




MES-Software

Configuration – customer data

Pos. Description



3 Announcement / choice of customers

4 Create new customer

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

customer

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

customer is created

7 Cancel the new customer data’s

8 Save new customer data’s




MES-Software

Configuration – generated orders

Pos. Description



3 Announcement and edit of generated orders, the chosen order is blue marked / all active orders get

marked in the last column of the table

4 Save orders




MES-Software

Inventory

Pos. Description

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

2 Choose sort of workpiece to edit workpiece in shelf

3 Cancel edits in inventory

6 Save edits in inventory




MES-Software

Show commissioning order

Only announcement of commissioning order.




MES-Software

7.4.1 Reference guide to create a new order

1.

Choose ‘New Orders’

2.

Click the Button ‘Add Orders’

3.

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

4. Set a start date and time

5.

Set a customer that is configured in the database

7.4 Create a new order




MES-Software

6.

Change the type of the order

7.

On a commissioning order a delay time and a output slide can chosen8.

On a commissioning order also the parts must be chosen

9. Positions can added or deleted with the Buttons

10.

Press ‘Ok’ when finished

11.

The Orders that are not enabled are listed in the TreeView

12. This Order can enabled, deleted or edited

13.

If the Order is enabled it is Deleted from the New Orders and you can find it in

the Overview




MES-Software

Situation:

Storage Station is on an Error

1.

A part is lost on the way to the Separating Station

2. A part was not gripped

The position of the order is started and BUSY

Workaround:

1.

Reset Storage Station

2.

Check the Storage content in the MES Software (ProductionControler) and

correct the content

3.

Rightclick on the Position with the wrong state (picture)

And click reset position

This position will be started again with first workorder

4. Start Storage Station in Automatic Mode (MES)

7.5 Workaround Error on

Storage Station




MES-Software




8.1.1

Standalone mode of Distributing Station

In standalone mode the Distributing Station distributes different types of

workpieces one after another. First red, then black, silver, red again, and so on. If a

magazine is empty, it automatically jumps to the next type of workpiece.

First we select the color. For example if the station distributes a red

previously, then it changes to black [spAuto].

According to the color of the workpiece to distributed, different cylinders will

be extended

[spExtRed / spExtBlack / spExtSilver]. If the magazine is empty, the station

will be on Idle state [stIdle].

When the workpiece arrives at the end of conveyor, the cylinder will be

retracted [spRetract].

Simultaneously the conveyor will stop 1 sec after the workpiece passes the

sensor at the end of conveyor [spStopConv].

Then the station will be on Idle state [spIdle].

Retract the cylinder at

the magazineEmpty: Wait 1 sec

Cylinder is retracted 1 sec later

spStopConv

Stop the conveyor

motor

Extend cylinder at

magazine 1

Extend cylinder at

magazine 2

Extend cylinder at

magazine 3

Empty: Jump back to

spIdle

Workpiece at

conveyor end (-3B1)

spRetract spWait1s

Black, and magazine 2

is not empty

Silver, and magazine 3

is not emptyElse

spExtRed spExtBlack spExtSilver spMagEmpty

spIdle

Station on Idle state

Station in standalone mode,

and next station is free

spAuto

Change color to the

next.

Red, and magazine 1

is not empty

8 Process description

8.1

Distributing Station

Sequence of distribution



Process description


8.1.2 MES mode of Distributing Station

In MES mode the Distributing Station cyclically asks for the task from the MES server

(in every second). It sends, the colors it has, and gets a task for one of these colors.

Firstly the station asks for the next task. It is done by a program called

MES_CyclicRequestForOrder. This program asks for a task, if the station is on

Idle state [spIdle]. It means the station sends an “Ask for a Task” message

(M100.1).

If it has a workpiece with the selected color, it sends a “Task Started”

message (M100.10).

[spRedStart / spBlackStart / spSilverStart].

According to the color of the workpiece to distributed, different cylinders will

be extended

[spExtRed / spExtBlack / spExtSilver].

When the workpiece arrives at the end of conveyor, the “Task Finished”

message (M101.1) will be sent by the station to the MES server

[spSendFinished].

Then the cylinder will be retracted [spRetract].

Simultaneously the conveyor will stop 1 sec after the workpiece passes thesensor at the end of the conveyor [spStopConv].

After that the station waits for next station [spWaitForValidation]. It has to

wait for validation, because, if the validation fails, it has to reproduce the

part.


Sequence of distribution



Process description


Extend cylinder at

magazine 2

Extend cylinder at

magazine 3

spSendFinished

Entry: Send "Task

Finished" (M101.1)

Workpiece at

conveyor end (-3B1)

spWaitForVali...

Empty: Wait for next

station (validation)

Next station finished

Station in MES mode, task rec eived, and

next station is free

Answer received Answer received

spExtRed spExtBlack spExtSilver

Extend cylinder at

magazine 1

Retract the cylinder at

the magazineEmpty: Wait 1 s ec

Cylinder is retracted 1 sec later

spStopConv

Stop the conveyor

motor

Entry: Send "Task

Started" (M100.10)

Entry: Send "Task

Started" (M100.10)

Entry: Send "Task

Started" (M100.10)

Empty: Jump back to

spIdle

Answer received

spRetract spWait1s

Answer received

Black, and magazine 2

is not empty

Silver, and magazine 3

is not empty Else

spRedStart spBlackStart spSilverStart spMagEmpty

spIdle


spMES

Registrate the color

Red, and magazine 1

is not empty

MES_CyclicRequestForOrder

Cylcically request for task in

every second.



Process description


8.2.1 Standalone mode of Testing Station

In standalone mode the Testing Station checks only the orientation of the

workpieces. If the workpiece is hole side up, then the station transports it to the next

station. If the workpiece is hole side down, then the station will transport it to the

waste slide.

If a workpiece arrives, the station switches the conveyor belt motor on, andwaits for 1 sec [spConveyorOn]

Then the station checks the orientation of the workpiece with a laser sensor[spCheck].

If the orientation of the workpiece is not ok:

o

The station extends the gate to the waste slide [spExtendGate].

o

The stopper cylinder will be retracted [spRetrStopper].o

Then the station waits until the workpiece arrives on the wasteslide [spWait3B1].

If the orientation of the workpiece is ok:

o

The station waits for the next station [spWaitNext].o

The stopper cylinder will be retracted [spRetrStopper].

o

The station waits until the next station starts working[spWaitNotNext].

o

Then waits for 1 sec more [spWait1s].

The gate is retracted (if it was extended), the stopper is extended, and theconveyor motor is stopped [spStop].

After the gate arrives to initial state, the station will be on Idle state [spIdle].

8.2 Testing Station

Sequence of validation



Process description


Gate in intial state

Save the workpiece type

After 1 sec

spStop

Retr. Gate, ext. Stop-

per, stop conveyor

Next station is free workpiece on slide

spWait1s

Empty: Wait 1 sec

Orienta tion wa s ok Orienta tion wa s not ok

spW ai tNotNe xt spW ai t3B1

Wait until next station

starts working

Empty: Wait until work

piece on slide

Empty: Wait until next

station is free

Extend gate to the

waste slide

Next station is free Gate extended

spRetrStopper

Retract the stopper

cylinder

spCheck

Check orientation

Orientation is ok Orientation is not ok

spW ai tNe xt spExte ndG ate

spIdle

Station in Idle state

Station in standalone mode, and

workpiece arrived

spConveyorOn

Switch on conveyor

belt motor

1 sec later



Process description


8.2.2 MES mode of Testing Station

In MES mode the Testing Station asks for the color from the MES server. If the

workpiece is hole side down, or the color does not match, the station will transport it

to the waste slide. If the color and orientation are good, the station transports the

workpiece to the next station.

If a workpiece arrives, the station switch the conveyor belt motor on, andwaits for 1 sec [spConveyorOn]

Then asks for task. It sends the “Ask for a Task” message (M100.1)[spAskForOrder].

If the station gets a task, it sends back a “Task Started” message (M100.10)[spSendStarted].

Then the station checks the workpiece with the color sensor, and lasersensor [spCheck].

If the color or the orientation of the workpiece is not ok, or there is notask:

o

The station extends the gate to the waste slide [spExtendGate].

o

The stopper cylinder will be retracted [spRetrStopper].o

Then the station waits until the workpiece arrives on the waste

slide [spWait3B1].o

Simultaneously the station sends “Task Finished with Error”message (M101.1 with error) [spSendError]

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

o

The station waits for the next station [spWaitNext].o

The stopper cylinder will be retracted [spRetrStopper].

o

The station waits until the next station starts working[spWaitNotNext].

o Then waits for 1 sec more [spWait1s].o Then the station sends “Task Finished” message (M101.1)

[spSendFinished].

The gate is retracted (if it was extended), the stopper is extended, and theconveyor motor is stopped [spStop].

After the gate arrives to initial state, the station will be on Idle state [spIdle].

Sequence of validation



Process description


(M101.1 with error)

spStop


per, stop conveyor


Registrate the workpiece type

spWait1s

Empty: Wait 1 s ec

After 1 sec

spSendFinished

Entry: Send "Task

Finished" (M101.1)

Answer received

Orientation or color

was not ok , or no task

spW ai tNotNe xt spW ai t3B1


starts working

Empty: Wait until

workpiece on slide

Next station is free workpiece on slide

spSendError

Entry: Send "Task

Finished with error"

Answer received

spRetrStopper

Retract the stopper

cylinder

1 sec later

Answer received

Orientation and color

are ok

Orientation and color

were ok

Empty: Wait until nextstation is free

Extend gate to thewaste slide

Next station is free Gate extended

spCheck

Check color and

orientation

spW ai tNe xt spExte ndG ate

Orientation or color is

not ok, or no task

spSendStarted

Entry: Send "Task

Started" (M100.10)

Entry: Send "Ask for a

Task" (M100.1)

Answer received

spAskForOrder

spIdle


Station in MES mode, and workpiece

arrives

spConveyorOn

Switch conveyor belt

motor on



Process description


8.3.1 Standalone mode of Processing Station

In standalone mode the Processing Station checks the hole in the workpiece, and if

it is hole side up, the station drills a hole in it. After that it will be transported to the

next station. Only one workpiece can be on the station in the same time.

The Processing Station does the same in MES mode.

If a workpiece arrives, the station waits for 1 sec [spWaits1s].

Then the indexing table rotates one step [sp_rotate1_1, spRotate2_1]. Then the testing unit moves down, and waits for 1 sec to reach the bottom

[spTesting].

The station checks the hole [spCheck]. Then it registrates the type of workpiece [spOk / spNotOk]. The testing unit moves up [spTestingUp].

Then the indexing table rotates one step again[sp_rotate1_2, spRotate2_2]

If the orientation of the workpiece was ok:

o

Fixes the workpiece [spFix].

o Switches the drill motor on, and the drilling unit moves down[spDrillDown].

o

The drilling unit moves up [spDrillUp].o

Switches the drill motor off [spDrillOff].

o

Releases the workpiece [spRelease].

Then the indexing table rotates one step again [sp_rotate1_3, spRotate2_3]. Waits until the next station is free [spWaitNext].

Ejects the workpiece to the next station [spEject].

Retracts the eject solenoid [spStop].

The station will be on Idle state [spIdle].

8.3 Processing Station

Sequence of processing



Process description


12

2

spEject

Eject workpiece to

next station

After 1 s ec

spStop

Retract the eject

solenoid

spRotate2_3

Reset start s ignal for

rotation of table

Table is in position

spWaitNext

Empty: Wait until next

station is free

Next station is free

spRelease

Release the workpiece

spRotate1_3

Give start si gnal for

rotation of table

Table is not in position

1

Drill unit is in bottom

position

spDrillUp

Drill unit moves up

Drill unit is in top

position

spDrillOff

Switch the drill motor

off

Hole side down

spFix

Fix the workpiece

After 1 s ec

spDrillDown

Switch the drill on, and

drill unit moves down

spRotate2_2


rotation of table


Hole side up

spTestingUp

Testing unit moves up

After 1 sec

spRotate1_2

Give start signal for

rotation of table


Testing unit moves

down

After 1 sec

spCheck

Empty: Check the hole

Hole side up

spTesting

spOk

Set workpiece type to

ok

spNotOk

Set workpiece type to

not ok

Hole side down


rotation of table


spRotate1_1Give start signal for

rotation of table


spRotate2_1

spIdle


Workpiece arrives

spWait1s

Empty: Wait 1 sec

1 sec later



Process description


8.4.1 Standalone mode of Pick & Place Station

In standalone mode the Pick & Place Station inserts a clock, a thermometer or a

hygrometer into the workpiece. The handling unit grips the instrument with a

vacuum, and inserts it on the workpiece.

The Pick & Place Station does the same in MES mode.

If a workpiece arrives the station extends the separator [spSepExt].

Then starts the conveyor [spConvOn]. After that it waits for 1 sec [spWait1s].

Then switch the conveyor off [spConvOff].

The handling unit moves down to the instrument [spDown]. The station switch the vacuum on to grip the instrument [spVacuumOn].

If the skipping of vacuum error is active ( xSkipVacError) then it will wait for2 sec [spWait2s], or wait until the signal comes from the vacuum sensor.

Then the station moves up with the instrument [spUp].

Extends the horizontal cylinder [spExtend].

Moves down to the workpiece to insert the instrument on it [spDown2]. Switches the vacuum off [spDrop]. Moves up [spUp2].

Retracts the horizontal cylinder [spRetract].

Simultaneously if the next station is free [spWaitNext], retracts theseparator, and switches the conveyor motor on [spSepRetr].

Waits for 1 sec for workpiece transport [spWait1s_2]. Switches the conveyor off [spConvOff2]. Then the station will be on Idle state [spIdle].

8.4 Pick & Place Station

Sequence of insertion



Process description


2 1

spWaits1s_2

Empty: Wait 1 sec

1 sec later

In upper position

12

spRetract

Retract the horizontal

cylinder


spSepRetr

Switch conveyor on,

retract separator

Workpiece at conveyor end

Move up

In upper position

spWaitNext

Empty: Wait for next

station

spVacuumOn

Switch vacuum on

Skipping the vacuum error is

active (xSkipVacError)

2 sec later

spUp2

spConvOff2

Switch the conveyor

motor off

Workpiece passes the s ensor before the

separator

spConvOff

Switch the conveyor

motor off

spDown

Move down to

instrument

Vertical cylinder is not

in upper position

spDown2

Move down with the

instrument

Not in upper position

spDrop

Switch the vac uum off

(drop the instrument)

No vacuum

Extend the horizontal

cylinder

Horizontal cylinder is

extended

Move up with the

instrument

spExtend

Empty: Wait 2 sec

spUp

Vacuum sensor is on

spWait2s

spConvOn

Switch the conveyor

motor on

spWaits1s

Empty: Wait 1 sec

1 sec later

spIdle


Workpiece arrives

spSepExt

Extend the separator



Process description


8.5.1 Standalone mode of Fluidic Muscle Press Station

In standalone mode the Fluidic Muscle Press Station presses the instrument into the

workpiece. It uses a pneumatic muscle for pressing.

The Fluidic Muscle Press Station does the same in MES mode.

If a workpiece arrives, the station waits for 2 sec [spWait2s].

Then closes the gripper and waits for another 1 sec [spClose].

Rotates to the processing position [spRotateProc]. The pressing unit moves down [spPressDown]. If the pressure is reached, the unit moves up [spPressUp].

Rotates to the downstream station [spRotateDown].

Then waits for the next station [spWaitDown].

If the next station is free, the horizontal cylinder is extended to thedownstream station [spMoveDown].

The station opens the gripper [spOpen], and waits for 1 sec.

The horizontal cylinder is retracted to the upstream station [spMoveUp].

Rotates to the upstream station [spRotateUp].

If the station reaches the initial position, the station will be on Idle state[spIdle].

8.5 Fluidic Muscle Press

Station

Sequence of pressing



Process description


Rotate to upstream

position

Rotary drive at upstream

station position

Open the gripper

1 sec later

spMoveUp


cylinder

Liner drive at upstream

position

spRotateUp

spWaitDown

Wait for next station


Rotary drive at downstream

station position

spOpen

spRotateDown

Rotate to the

downstream station

spPressUp

Pressing unit moves

up

2 sec later

Pressing unit moves

down

Pressure reached

Rotate to the

processing position

Rotary drive at

processing position

spPressDown

Close the gripper

1 sec later

spRotateProc

Empty: Wait 2 sec

2 sec later

spClose

spIdle


Workpiece arrives

spWaits2s



Process description


8.6.1 Standalone mode of Storing Station

In standalone mode there are two tasks (insertion, removal). The station switches

between each of the tasks one after the other.

The first task is inserting the incoming workpiece into the storage. Each colors are

sorted on different shelves (from the top: red, black, silver). The station searches

from the right side for an empty tray. If there is no free place for the workpiece, it will

be transported to the next station.

The second task is the removal. If the next station is free, the Storing Station

searches for the color, which occurs the most, and transports it from the storage to

the next station. The station searches from the right side for a workpiece.

If a workpiece arrives the station moves above the workpiece[spMoveAboveIn_c1].

It clears the number of failed color checks [spCheckNum0_c1].(It should count the number of fails of color checks, because if it failed threetimes in a row, there is a problem with the color sensor, and the station hasto go to error state.)

Then the station extends the horizontal cylinder [spExtend_c1].

Then it checks the color [spCheckColor_c1].

If the color check fails:

o Retracts the horizontal cylinder, and increases the number of failedcolor checks [spRetract_c1].

o

Then checks whether there is still a workpiece or not[spCheckWp_c1].

o

If there is still a workpiece jumps back before color check[spExtend_c1], else the station jumps back to Idle state [spIdle].

Then the station search for an empty tray for workpiece [spSearchIPlace]. Ifthere is no free place, the workpiece will be transported to the next station.

Moves down to the workpiece [spMoveIn_c1]. Closes the gripper [spClose_c1]. Moves up with the workpiece [spMoveAboveIn_c2]. Retracts the horizontal cylinder [spRetract_c2].

Moves above the empty tray, or above the input of the next station[spMoveAboPlace_c1].

8.6 Storing Station




Process description


If the workpiece was transported to the next station :

o

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

Extends the horizontal cylinder [spExtend_c2].

Moves to the tray or to the input of the next station [spMovePlace_c1].

Opens the gripper [spOpen_c1].

If the workpiece was transported to a tray :

o

Registrates the insertion [spRegIns_c1].

Retracts the horizontal cylinder [spRetract_c3].


1 2

spWaitNext_c1

Wait for next station


Insertion into

the storage not

to the next

station

1

spRetract_c3

Retract horizointal

cylinder

Horizontal cylinder

retracted

Else

Else

2

If inserted into the

storage

spRegIns_c1

Registrate the

insertion

1 sec later

If there is no free

place select the

next station for

insertion.

There is a

workpiece

Horizontal cylinder

extended

spMovePlace_c1

Move to the place

Motion finished

spOpen_c1

Open the gripper

Horizontal cylinder

retracted

spMoveAb.Pl._c1

Move above the place

Motion finished

spExtend_c2


cylinder

Close the gripper

1 sec later

spMoveAb.In_c2

Move above the up-

stream station pos.

Motion finished

spRetract_c2

Station in standalone mode, insertion is

selected, and workpiece arrives

spMoveIn_c1

Move to the upstream

station position

Motion finished

spClose_c1

Empty: Check if there

is a workpice or not

There is no workpiece

(it was removed)

Retract horizointal

cylinder

Search free place for

insertion

Retract horizointal

cylinder

In entry action increase the

number of color checks

Horizontal cylinder

retracted

spCheckWp_c1

spCheckColor_c1

Check and registrate

the type of the wp.

Workpice color was

detectedElse

spSearchIPlace spRetract_c1

1 sec later

spCheckNum0_c1

Reset the number of

color checks

spExtend_c1


cylinder

Horizontal cylinder

extended

spIdle


spMoveAb.In_c1

Move above the up-

stream station pos.

Motion finished



Process description


If the removal is active the station selects the color, which occurs the most[spSelColor_d1].

Then it searches for a tray, which has a workpiece with the same color[spSearchRPlace].

If there is not a workpiece in the storage with the specific color of theorder:

o

The station jumps back to Idle state [spIdle].

Then the station moves to the workpiece [spMovePlace_d1].

Extends the horizontal cylinder [spExtend_d1].

Closes the gripper [spClose_d1]. Lifts up the workpiece [spMoveAbovePlace_d1].

Registrates the removal [spRegRam_d1].

Retracts the horizontal cylinder [spRetract_d1].

Moves above the input of the next station [spMoveAboveOut_d1].

Extends the horizontal cylinder [spExtend_d2]. Moves to the input of the next station (uses only the linear axes)

[spMoveOutLin_d1].

Opens the gripper, drops the workpiece [spOpen_d1].

Retracts the horizontal cylinder [spRetract_d2].


Sequence of removal



Process description


spRetract_d2


cylinder

Horizontal cylinder

retracted

1 2

1 2

Station in standalone mode, removal is

selected, and the storage is not empty

spExtend_d2


cylinder

Horizontal cylinder

extended

spMo.OutLin_d1

Move to downstream

station (only linear)

Motion finished

spRetract_d1


cylinder

Horizontal cylinder

retracted

spMo.Ab.Out_d1

Move above

downstream station

Motion finishedElseIf there is a wp. with

the selected color

spMoveAb.Pl._d1


Motion finished

spRegRem_d1

Registrate the

removal

spOpen_d1

Open the gripper

1 sec later

spClose_d1

Close the gripper

1 sec later

spExtend_d1


cylinder

Horizontal cylinder

extended

Search for the selec-

ted color in storage

spMovePlace_d1

Move to the place

Motion finished

Select color (which

occurs the most)

spSearchRPlace

spIdle


spSelColor_d1



Process description


8.6.2 MES mode of Storing Station

In MES mode there are two tasks (insertion, removal). The station switches between

each of the tasks one after the other.

The first task is inserting the incoming workpiece into the storage. After the station

detects the color, it asks for a task from MES server. If there is an order for the

specific color of the workpiece, it will serve it. If there is no order for the color, the

station asks the MES server for an empty tray, and inserts the workpiece into this

tray. If there is no free place, the workpiece will be transported to the next station.

The second task is the removal. If the next station is free, the Storing Station asks

the MES server for an order. If there is an order, the station transports it from the

storage to the next station.

If a workpiece arrives the station moves above the workpiece[spMoveAboveIn_a1].

It clears the number of failed color checks [spCheckNum0_a1].(It should count the number of fails of color checks, because if it failed threetimes in a row, there is a problem with the color sensor, and the station has

to go to error state.) Then the station extends the horizontal cylinder [spExtend_a1].

Then it checks the color [spCheckColor_a1].

If the color check fails:

o

Retracts the horizontal cylinder, and increases the number of failedcolor checks [spRetract_a1].

o Then checks whether there is still a workpiece or not[spCheckWp_a1].

o If there is still a workpiece jumps back before color check[spExtend_a1], else the station jumps back to Idle state [spIdle].

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

[spAskForOrder_a1).




Process description


If there is an order for the station:

o

It asks for the parameters of the order (M100.21)[spAskForParameters_a1].

o

Then registrates the color from the answer [spSaveColor_a1].

o If the color of workpiece and order match:

The stations ends “Task Started” message (M100.10)[spSendStarted_a1]

Moves to the workpiece [spMoveIn_a1]. Closes the gripper [spClose_a1].

Lifts up the workpiece [spMoveAboveIn_a2].

Retracts the horizontal cylinder [spRetract_a2].

Moves above the input of next station[spMoveAboveOut_a1].

Waits until the next station is free [spWaitNext_a1].

Extends the horizontal cylinder [spExtend_a2].

Moves to the input of the next station (use only the linearaxes) [spMove.OutLin_a1].

Opens the gripper, drops the workpiece [spOpen_a1]. Retracts the horizontal cylinder [spRetract_a3].

Send a “Task finished” message (M101.1)[spSendFinished_a1].

Then the station jumps back to Idle state [spIdle]. Then the station asks for an empty tray for the workpiece from MES

[spSearchMESIPlace].

Then the station calculates the row and column number from the traynumber [spCalcColRowI_a1]. If there is no empty tray, the workpiece will betransported to the next station.

Moves down to the workpiece [spMoveIn_a2]. Closes the gripper [spClose_a2]. Moves up with the workpiece [spMoveAboveIn_a3].


Moves above the empty tray, or above the input of the next station[spMoveAboPlace_a1].

If the workpiece was transported to the next station :

o

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

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

If the workpiece was transported to a tray :

o

Registrates the insertion [spRegIns_c1].o

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





Process description


1 2 3 4

Station in MES mode, insertion is selected,

and workpiece arrives

Motion finished

Else

spCalcColRowI_a1

Calculate the row and

column number

Answer received

spSendStarted_a1

Entry: Send "Task

Started" (M100.10)

Answer received

spMoveIn_a1

There is a

workpiece

There is no workpiece

(it was removed)

spAskForPara._a1

Entry: Ask for param.

(M100.21)

Answer received

spSaveColor_a1

pAskForOrder_a1

Entry: Ask for an order

(M100.1)

Answer received

There is no tas k for the

stationElse

In entry action increase the

number of color checks

Empty: Check if there

is a workpice or not

spCheckWp_a1

Workpice color was

detectedElse

spSearchMESIPla.

If there is no free

place select the

next station for

insertion.

spRetract_a1

Search free place for

insertion

Retract horizointal

cylinder


cylinder

Horizontal cylinder

extended

spCheckColor_a1

Check and registrate

the type of the wp.

1 sec later

Reset the number of

color checks

spExtend_a1

Registrate color from

answer

Task and workpiece

color do not match


station position

Move above the up-

stream station pos.

Motion finished

spCheckNum0_a1

spIdle


spMoveAb.In_a1

Horizontal cylinder

retracted



Process description


Answer received

3 4

spRegInsMES

1 sec later

spRetract_a3

Retract horizointal

cylinder

Horizontal cylinder

retracted

spSendFinish._a1

Entry: Send "Task

Finished" (M101.1)

Horizontal cylinder

extended

spMov.OutLin_a1

Move to downstream


Motion finished

spOpen_a1

Open the gripper

Motion finished

spWaitNext_a1



spExtend_a2


cylinder

Motion finished

spRetract_a2

Retract horizointal

cylinder

Horizontal cylinder

retracted

spMov.Ab.Out_a1

Move above the down-

stream station pos.

spClose_a1

Close the gripper

1 sec later

spMoveAb.In_a2

Move above the up-

stream station pos.

1 sec later

spRetract_a5

spMoveAb.In_a3

Retract horizointal

cylinder

Move above the up-

stream station pos.

Horizontal cylinder

retracted

Motion finished

Entry: Registrate the

insertion in MES

Else

Motion finished

spRegIns_a1

spClose_a2

Registrate the

insertion

Close the gripper

spOpen_a2

Open the gripper

spMoveIn_a2

1 sec later


station position

If inserted into the

storage

Move to the place

Motion finished


spExtend_a3


cylinder

Horizontal cylinder

extended

spMovePlace_a1

Insertion into

the storage not

to the next

station

Else

spWaitNext_a2


spMoveAb.Pl._a1


Motion finished

1 2

spRetract_a4

Retract horizointal

cylinder

Horizontal cylinder

retracted



Process description


If the removal is active, and there is an order the station asks for theparameters of the order (M100.21) [spAskForParameters_b1].

Then it asks from the MES for a tray, which has a workpiece with the samecolor (M100.30) [spSearchRPlace].

If there is not a workpiece in the storage with the specific color of theorder:

o

The station jumps back to Idle state [spIdle].

Then the station sends a “Task started” message (M100.10)[spSendStarted_b1].

Moves to the workpiece [spMovePlace_b1]. Extends the horizontal cylinder [spExtend_b1].

Closes the gripper [spClose_b1].

Lifts up the workpiece [spMoveAbovePlace_b1].

Registrates the removal [spRegRam_b1]. And simultaneously registrates the removal in MES [spRegRemMES]. Retracts the horizontal cylinder [spRetract_b1].

Moves above the input of the next station [spMoveAboveOut_b1].

Extends the horizontal cylinder [spExtend_b2].

Moves to the input of the next station (uses only the linear axes)[spMoveOutLin_b1].

Opens the gripper, drops the workpiece [spOpen_b1]. Retracts the horizontal cylinder [spRetract_b2].

Sends a “Task finished” message (M101.1) [spSendFinished_b1]. Then the station will be on Idle state [spIdle].

Sequence of removal



Process description


spSendFinish._b1

Entry: Send "Task

Finished" (M101.1)

Answer received

1 2

Answer received

spSendStarted_b1

Entry: Send "Task

Started" (M100.10)

Answer received

pSearchMESRPla.

Entry: Ask for place

from MES (M100.30 )

Answer received

pSea.MESRPl._b1

spMoveAb.Pl._b1

spRetract_b2



cylinder

Motion finished

Horizontal cylinder

retracted

spRegRemMES

Entry: Registrate the

removal in MES

Answer received

Station in MES mode, removal is selected,

and there is an order

spClose_b1

spOpen_b1

Close the gripper

Open the gripper

1 sec later

1 sec later

spExtend_b1

spMo.OutLin_b1


cylinder

Move to downstream


Horizontal cylinder

extended

Motion finished

spMovePlace_b1

spExtend_b2

Move to the place


cylinder

Motion finished

Horizontal cylinder

extended

Calculate the column

and row from param.

spMo.Ab.Out_b1

Move above

downstream station

If there is a wp. with

the selected colorElse

Motion finished

Answer received

spAskForPara._b1

Entry: Ask for

parameters (M100.21)

spRetract_b1


cylinder

Horizontal cylinder

retracted

spCal.Co.Ro.R_b1

Entry: Search for tray

with MES

1 2

spIdle

Station on Idle statespRegRem_d1

Reistrate the removal



Process description


8.7.1 Standalone mode of Separating Station

In standalone mode the Separating Station transports the black and silver

workpieces to the Robot Station with the separator gate, and transports the red

workpiece to the Sorting Station. In this case the station uses all sensors, so we can

check whether they are working or not.

After a workpiece arrives the station waits for 2 sec [spWait2s]. (It waits forthe Storing Station.)

Then switches the main conveyor motor on [spConv1On]. After the workpiece arrives to check point it waits for 1 sec [spWait1s]. Then it checks the color and material [spCheck].

If the color of the workpiece is black or silver:

o

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

If the color of the workpiece is red:

o

Registrates that the workpiece was not good [spNotOk].

Then the station waits for the next station [spWaitNext].

After the next station is free, the station retracts the stopper [spRetrStop].

After the workpiece arrives at the end of either of conveyor, the stationwaits for 2 sec [spWait2s_2].

2 sec later it retracts the separator, extracts the stopper and stops theconveyors [spStop].

After that the station will be on Idle state [spIdle].

8.7 Separating Station

Sequence of separation



Process description


Separator is not

retracted


Check and reg. the

type of the workpiece

Workpiece is black or

silverElse

spExtGate spNotOk


and switch conv. 2 on

Save that the work-

piece was not good


spCheck

Empty: Wait 1 se c

spStop


per, stop conveyors

1 sec later

Switch the main

conveyor on

spWait2s_2

Empty: Wait 2 se c

Workpiece at check

position

2 sec later

spWait1s

Wait for sorting or for

the robot buffer.


arrives


spWait2s

Empty: Wait 2 se c

spRetrStop

Retract the stopper

2 sec later

Workpiece arrives at the

end of any conveyor

spConv1On

spIdle


spWaitNext


is free



Process description


8.7.2 MES mode of Separating Station

In MES mode the Separating Station asks the server about the next order. If the

coming workpiece has the same color than the order, the station transports it to the

Robot Station with the separator gate. If the color of the workpiece is not correct, it

will be transported to the Sorting Station.

After a workpiece arrives the station waits for 2 sec [spWait2s]. (It waits forthe Storing Station.)

Then switches the main conveyor motor on [spConv1On]. After the workpiece arrives to check point it waits for 1 sec [spWait1s]. Then the station asks for an order (M100.1) [spAskForOrder].

If it gets a task, it sends a “Task Started” message (M100.10)[spSendStarted].

Then it checks the color and material [spCheck].

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

o

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

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

o

Registrates that the workpiece was not good [spNotOk].

Then the station waits for the next station [spWaitNext].

After the next station is free, the station retracts the stopper [spRetrStop].

After the workpiece arrives at the end of either of conveyor, the stationwaits for 2 sec [spWait2s_2].

2 sec later it retracts the separator, extracts the stopper and stops theconveyors [spStop].

If the workpiece was good, the station inserts the workpiece into the buffer(M100.36) of the Robot Station [spInsertFIFO].

According to the type of the workpiece, the station sends a “Task Finished”message (M101.1) with or without error [spSendFinished].

After that the station will be on Idle state [spIdle].

Sequence of separation in

MES mode



Process description


2 1

2 1


Answer received

If the workpiece was good

spSendFinished

Entry: Send "Task

Finished" (M101.1)

Answer received

Accorindg to the workpiece

type, with or without error.

If there was a task.

Wait for s orting or for

the robot buffer.

Workpiece arrived to the

end of either of conveyor

spWait2s_2

Empty: Wait 2 sec

spStop


per, stop conveyors


Answer received

spSendStarted

Entry: Send "TaskStarted" (M100.10)

Answer received

If there is a task for thestation.

spCheck

Check and reg. the

type of the workpiece


spRetrStop

Retract the stopper

2 sec later

spInsertFIFO

Entry: Insert wp. In

rob. FIFO (M100.36)


is free


and switch conv. 2 on

Reg. that the work-

piece was not good

Separator is not

retracted

spWaitNext

spAskForOrder

Entry: Send "Ask For a

Task" (M100.1)

Workpiece is good Else

spExtGate spNotOk

spConv1On

Switch the main

conveyor on

Workpiece at check

position

spWait1s

Empty: Wait 1 sec

1 sec later

spIdle



arrives

spWait2s

Empty: Wait 2 sec

2 sec later



Process description


8.8.1 Standalone mode of Sorting Station

In standalone mode the Sorting Station sorts out the different types of workpieces

to different slides.

The Sorting Station does the same in MES mode.

If a workpiece arrives the station switches the conveyor motor on and waitsfor 2 sec [spConvOn].

Then checks the color and the material with an inductive-, and an opticalsensor.

According to the material and color, the station extends a separator or not[spExtRed / spExtBlack / spExtSilver].

Then retracts the stopper [spRetrStoper].

Waits for the falling edge of the sensor at the slides (-B4) [spWaitNotB4].

Retracts the separator (if it was extended), and extends the stopper[spStop].

If all separators are retracted, the station will be on Idle state [spIdle].

8.8 Sorting Station

Sequence of sorting



Process description


spExtSilver

Do not extend any

separator

Workpiece is silver

Second separator is

extended

First separator is

extended

spExtBlack

Extend the second

separator

spWaitNotB4

Empty: Wait unti l

sens or is off at slide

The sensor at the slide

is off

spStop

Retr. Sep., ext. Stopper

switch conveyor off

Separators are

retracted

spExtRed

Extend the first

separator

spRetrStoper

Retract the stopper

The sensor at the slide

is on

spIdle


Workpiece arrives

spConveyorOn

Switch the conveyor

motor on

Workpiece is red Workpiece is black



Process description


8.9.1 Standalone mode of Robot Station and Robotinos

In standalone mode the Robot Station and the Robotinos work only in a simple

sequence (in an infinite loop). The Robotino 1 moves an empty pallet from the input

slide to the Robot Station. The Robot moves it to the next pallet place, and then

commissioned it with for workpieces. The Robot moves the commissioned pallet to

the output slide. The Robotino 1 transports it to the next position of the stock, and

moves back to the output slide of the Robot Station. After that the Robotino 2

removes the pallet from the stock, and transports it to the next outline. Then the

Robot Station starts the cycle again. Between the cycles the Robot Station and

Robotinos switch to the next pallet position, stock position, and outline one after the

other. In this case all positions will be tested in standalone mode. There is only one

pallet in the system in the same time. The operator should remove manually the

delivered pallet from the outline, and place a new empty pallet on the input slide.

First the station initializes the variables [1].

Then it waits for an empty pallet on input slide [10].

The station sends the Robotino 1 to move the empty pallet to Robot Station[15].

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

o

The station jumps back to Idle state [10].

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


o The station jumps back to Idle state [10].

Then it waits until the workpiece arrives at the end of input slide [100].

The Robot moves the pallet to the next empty pallet place [105].

And waits until a workpiece arrives at conveyor belt [110]. Then the Robot moves the workpiece to the next free place of the pallet

[115].

And calculates the next workpiece position [120].

If there is still a free place on the pallet:

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

Then the station waits until output slide of the Robot is free [125].

After that it lifts up the pallet stopper [130]. And the Robot moves the commissioned pallet to the output slides [135]. Then waits until the Robot finishes the task [140].

After that the station writes the RFID data into the pallet [145].

And waits until the writing is finished [150].

8.9 Robot Station and

Robotinos

Sequence of robot station

and robotinos



Process description


Then it lifts down the pallet stopper [155].

And waits until the pallet arrives at the bottom of output slide [160].

Then calculates the next pallet place [165]. The station switches betweenthe pallet position one after the other to check all positions.

If all pallet places have been already used, starts with the first place again[170].

Then the station sends the commissioned pallet to the stock with Robotino1 [175].


o

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

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


o


After the Robotino 1 finishes the task, the station calculates the outlineposition [185].

If Robotino 2 is ready, Robotino 2 moves the pallet from the stock to theoutline [190].


o


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


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

After the Robotino 2 finishes the task, the station calculates the outlineposition [200].

After the pallet arrives at the bottom of the outline slide (RFID tag isdetected), the station reads out the RFID data from the pallet [205].

And then the station calculates the next storage and output position [250].The station switches between the storage, and output positions one afterthe other to check all positions.

If all storage positions, or all outlines have been already used, start againwith the first storage position or outline [255].

Then jump back to Idle state [10] from an empty step [300].



Process description


4

2 1

5 3

Pallett stopper in lower position

and pallett at slide end

2 1

Error in Robotino 2

communication

Error in Robotino 1

communication

Error in Robotino 1

communication

190

move pall. to outline

with Robotino 2

Robotino 2 is busy

(started the task)

Error in Robotino 1

communication

175

Next storage position is free, and

Robotino 1 is ready

Calculate the outline

position

Robotino 2 is ready

Send pallet to the

stock with Robotino 1

Robotino 1 is busy

(started the task)

180

Empty: Wait until

Robotino 1 finished

165

Switch to the next

pallet position

170If next pos. > 4 change

to pal. Pos 1

185

Robotino 1 is ready

After that the Robotino 1 will go back to

Robot Station

135

Move the pallet to

output slide

160

Wait until pallet at

slide end

145

Write RFID data into

pallet

150

Wait RFID write

finished

RFID write finished

Else

155

Lift down the pallet

stopper

130

Lift up the pallett

stopper

Pallett stopper in

upper position

140

Wait until robot task

finished

Robot finished the

task

Empty pallet is on

Robot's input slide

105

The next pallet position is

stored in byPalPos

The index is 1 again

125

Robot finished the

task

120

Switch to the next

position on pallet.

Workpiece available

at conveyor belt

Robot's output slide is

free

Station in standalone mode, and buffer

and storage are empty

Error in Robotino 1

communication

100

Wait for empty pallet

on Robot slide

Empty: Wait for Robot

outslide is free

115

Move workpiece to the

next position on pall.

The next position on pallet is

stored in byPalIndex

Move the empty pallet

to next pallet position

Robot finished thetask

110

Empty: Wait for

workpiece at conveyor

15

Send Robotino 1 for an

empty pallet

Robotino 1 is busy

(started the task)

20

Empty: Wait until

Robotino 1 finished

Robotino 1 is ready

1

Initalize variables

10

Wait for Auto Mode



Process description




Process description


8.9.2 MES mode of Robot Station

In MES mode there are three tasks (empty tray insertion, commissioning and

delivery of commissioned pallet). The station tries to avoid serving the same task

twice in a row. The empty tray insertion has the highest priority, then the

commissioning, and the delivery.

The first task is inserting the incoming empty pallet to a free pallet place. If there is

an empty pallet on input slide, and there is a free pallet place, the station moves the

pallet to the free place, and registrates the insertion in MES server.

The second task is the commissioning. If there is a pallet on a pallet place, a

workpiece on the conveyor, and the last insertion was more than 1s before, the

Robot asks for an insertion task form MES, and moves the workpiece to the specific

place.

The third task is the delivery of commissioned pallet. If there is a pallet at a pallet

place, the output slide is free, and the last delivery was more than 1s before, the

Robot ask for a delivery task from MES, and it moves the specific pallet to the output

slide.

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

If there is no free place:

o


The Robot moves the pallet from the input slide to the specific pallet place[110].

Waits until the Robot finishes the task [115].

After the Robot finishes, the station checks the return code from the Robot[116].

After the return code is 0 the station books the pallet in pallet buffer of MESserver (M100.31) [120].

Then the station waits for the answer from MES [125].

After that the station will be on Idle state [10].

Sequence of empty pallet

insertion



Process description


MES mode is active, there is an empty pallet on

input slide, and one of the pallet places is free

Else

115

Wait until Roboto

finishes the task

Empty: Wait MES

request finished

Answer received

book pallet on MES

pall. buffer (M100.31)

125

Check robot return

code

Return code = 0

120

Robot finished the

task

116

110

Move the pallet from

the input to the place

100

Search for the next

free pallet place

There is a free place

10




Process description


If there is a workpiece on the conveyor belt, there is a pallet on a palletplace, and the last workpiece insertion was more than 1s before, the stationregistrates the start of commissioning [200].

Then it asks for a commissioning task from MES (M100.2) [205]. And waits for the answer [210].

If there is no task for commissioning:

o


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

If there is no place for insertion:

o


The station sends a “Task started” message (M100.10) to the MES [225].

And waits for the answer [230].

Then the station moves the workpiece to the pallet [250]. And waits until the Robot finishes the task [255].

Checks the return code from the Robot [256].

After the return code is 0, the station removes the workpiece from the FIFOof MES server (M100.37) [260].

And waits for the answer from MES [265].

Then the station sends a “Task finished” message (M101.1) [270]. And waits for the answer [275].

After the answer received, the station will be on Idle state [10].

Sequence of commissioning

a pallet



Process description


275

Empty: Wait MES

request finished

Answer received2 1

2 1

265

Empty: Wait MES

request finished

Answer received

270

Send "Task Finished"

(M101.1)

256

Check Robot return

code

Return code = 0

260

Remove workpiece

from FIFO (M100.37)

250

Move the workpiece to

the pallet

255

Empty: Wait until

robot finish

Robot finished the

task

225

Send "Task Started"

(M100.10)

230

Empty: Wait MES

request finished

Answer received

Else

MES mode is active, there is a workpiece on

conveyor, other is a pallet, and last workpiece

insertion was more than 1 s ec before.

There is a place for

insertionElse

Answer received

There is a task for

Insertion

215

Ask MES, where to

place wp. (M101.35)

220

Empty: Wait MES

request finished

205

Check if order i n MES

available (M100.2)

210

Empty: Wait MES

request finished

Answer received

10


200

Registrate the start of

insertion



Process description


If there is a pallet on a pallet place, the output slide is free, and the lastdelivery was more than 1s before, the station registrates the start ofdelivery [300].

Asks for a delivery task from MES (M100.2) [305]. And waits for the answer [310].

If there is no task for delivery:

o


The station asks the MES, which pallet should be delivered (M100.30) [315]. And waits for the answer [320].

The station sends a “Task started” message (M100.10) to the MES [325].


Then it lifts up the pallet stopper [345]. And waits until the stopper reaches the upper position [350]. If the stopper is in upper position, the Robot moves the pallet to the output

slide [355].

Then the station waits until the Robot finishes the task [360].

After that it checks the return code from the Robot, and waits until it is 0[361].

The station writes the RFID data into the pallet [365]. And waits until the writing is finished [370].

Then lifts down the pallet stopper [375].

And waits until the pallet reaches the bottom end position of the outputslide [380].

Then the station updates the buffer position (removes the delivered pallet)in MES (M100.31) [390].

And waits for the answer [395]. Then it sends a “Task finished” message (M101.1) to the MES [400].


After the answer received, the station will be on Idle state [10].

Sequence of delivering the

commissioned pallet



Process description


2 1

2 1

MES mode is active, there is a pallet on pal l. place,

output slide is free, and las t delivery was more than

1 sec before.

ElseTher is a task

395

Empty: Wait MES

request finished

Answer received

405

Empty: Wait MES

request finished

Answer received

390

Update buffer in MES

(M100.31)

380

Wait until pallet at

slide end

Pallett stopper in lower position

and pallett at slide end

400

Send "Task fininshed"

(M101.1)

Pallet stopper in

upper position

Write RFID datat into

pallet

361

Check Robot return

code

Return code = 0

360

Empty: Wait until

robot finishes

Robot finished the

task

345

Lift up pallet stopper

375

Lift down pallet

stopper

370

Wait RFID write

finished

RFID write finished

365

355

Move commissioned

pallet to out slide

350

Wait pallet stopper in

upper end position

Pallet stopper in

upper position

325

Send "Task started"

(M100.10)

330

Empty: Wait MES

request finished

Answer received

Answer received

315

Search for the pallet to

move (M100.30)

320

Empty: Wait MES

request finished

Answer received

305

Check if order in MES

available (M100.2)

310

Empty: Wait MES

request finished

Robot finished the

task

10


300

Registrate the start of

delivery



Process description


8.9.3 MES mode of Robotino 1

In MES mode there are two tasks for Robotino 1 (commissioned pallet transportation

from Robot Station to Robotino Storage, empty tray transportation to Robot

Station). The commissioned pallet transportation has a higher priority.

If a pallet is on the output slide of Robot Station, the Robotino asks the MES about

next task. If there is a task, the Robotino transports the pallet to a free storage

position, and registrates it in MES. After that the Robotino moves back to Robot

Station.

If an empty pallet is available on the input slide, and the input slide of the Robot

Station is free, the Robotino moves the empty pallet to the Robot Station. In this

case the Robotino does not have any communication with the MES server.

If a pallet is on the output slide of Robot Station, the Robotino asks the MESabout next task (M100.2) [200].

And waits until the answer received from MES [210].

If there is no task:

o


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

to the Robotino Storage [230].

And waits until the Robotino is busy [235].

If there is a communication error between Robotino and PLC:

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

Then the station waits until Robotino finishes [240].


o

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

Then the PLC books the Robotino Storage position in MES server (M100.31)[245].


Then sends a “Task finished” message (M101.1) to MES [255].


Then the Robotino will be on Idle state.

Sequence of commissioned

pallet transportation to

storage



Process description


10


MES mode is active, there is a pa llet on output slide

at Robot Station, and there is a free place in the

storage

2 1

230

Send "Task started"

(M100.10)

225

220

Find next free shelf in

storage

Free place found

Answer received

Ther is a task Else

215

210

Empty: Wait MES

request finished

200

Ask for a ta sk from MES

(M100.2)

245

Empty: Wait untilRobotino is busy

Robotino moves the

pallet to sock.

235

Robotino is busyError in Robotino

communication

240

Empty: Wait until

Robotino finished

Robotino finished Error in Robotino

communication

Empty: Wait MES

request finished

Answer received

Answer received

Book pallet on MES

stock buffer (M100.31)

Free place found

250

Empty: Wait MES

request finished

Answer received

255

Empty: Wait MES

request finished

2 1

Send "Task finished"

(M101.1)

Free place found

260



Process description


If an empty pallet is available on the input slide, and the input slide of theRobot Station is free, the Robotino moves the empty pallet to the RobotStation [100].

And the PLC waits until the Robotino is busy [105].


o

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

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


o


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

10


Error in Robotino

communicationRobotino finished

Empty: Wait until

Robotino finished

110

Error in Robotino

communicationRobotino is busy

Empty: Wait until

Robotino is busy

105

MES mode is active, there is a pallet on input sl ide, and

the input slide of Robot Station is free

100

Robotino moves

empty pallet to Robot

Sequence of empty pallet

transportation to the Robot

Station



Process description


8.9.4 MES mode of Robotino 2

In MES mode the Robotino 2 has only one task (Transportation of commissioned

pallet from Robotino Storage to outline slide). Before the delivery the PLC asks the

MES server about the destination of the pallet. If the destination is not defined, the

PLC selects the next free output slide.

If there is a free output slide, and a pallet in the Robotino Storage, theRobotino asks for parameters of pallet delivery (M100.41) [100].


If there is no task for delivery:

o


After that the Robotino selects the destination slide. If there is a predefinedslide, the Robotino selects that. If there is not a predefined slide, theRobotino selects the first free output slide from the left [115].

Then the PLC sends a “Task started” message (M100.10) to the MES [120].


The Robotino transports the pallet form the storage to the selected outputslide [130].

And the PLC waits until Robotino is busy [135].


o


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


o


The PLC updates the Robotino Storage buffer in MES (M100.31) [145].


Then the PLC sends “Task finished” message (M100.31) to MES [155].


After the answer is received, the station will be on Idle state [10].

Sequence of pallet delivery

to output slides



Process description


2 1

2 1

155

Send "Task finished"

(M101.1)

160

Empty: Wait MES

request finished

Answer received

145

Update storage buffer

in MES (M100.31)

150

Empty: Wait MES

request finished

Answer received

Error in Robotino

communication

140

Empty: Wait until

Robotino finished

Robotino finished Error in Robotino

communication

130

Robotinio moves the

pallett to out. slide

125

Empty: Wait MES

request finished

Answer received

135

Empty: Wait until

Robotino is busy

Robotino is busy

110Empty: Wait MES

request finished

Answer received

115

Select output slide

There is a delivery task

from storageElse

120

Send "Task started"

(M100.10)

10


MES mode is active, there is a free output slide, there is

a pallet in the Robotino storage

100

Get parameters for

delivery (M100.41)




This chapter refers to the technology of the system.

The conveyor belt, with a width of 40 mm, is driven by 24 V-engines, which results in

an average transport speed of about 9 m/min.

For better construction understanding of the station, the technical drawings should

be a very helpful data.

The rooms must be checked for their technical datas before built up the

station/system. The size of the door openings and the entrance must be big enough

for the measurements of the system. Even the load-capacity of the floor must be

high enough for the system.

Technical drawing

9 Technology

9.1 drawings



Technology


The conveyor system is made up of a number of different function modules, some of

which are also used in the field of MPS-Plus.

Pallet

Work pieces

9.2.1

Pallet

Responsible for the transport of 4 processed or unprocessed cylinders. The palette

can be moved from the robot by means of the reception aid at the center of the

palette. On the bottom side there is the RFID Sensor.

Measurements: 164 x 164 mm

Pallet 1BPW

9.2 Modules in use



Technology


9.2.2 Work pieces

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

silver work pieces are available.

Work pieces

http://www.dict.cc/englisch-deutsch/distinguish.html

http://www.dict.cc/englisch-deutsch/distinguish.html



Technology





The pressure in the supply line must not exceed 10 bar.

A fine filter has to be installed, to prevent contamination by rust or similar.

A stop cock is required for the supply of the installation.

The pressure regulators should be set in between 5 and 6 bar. The filter and water

separators require maintenance according to the instructions of the documentation

of these components.

The exact allocation of the valve terminal can be found in the pneumatic plan.

Service unit

10 Pneumatic

10.1 Pneumatic supply



Pneumatic





To operate the system it is required to connect all of the supply cables andcommunication lines included. The cables used to program the system are explained

additionally.

To give you a better survey of the being lines used in the plant, these are explained

in the following.

The devices are delivered together with the respective power supply plugs,

protectively contact covered, in case they require power supply.

The customer must ensure that the power supply is earthed correctly and is

equipped with a fault current monitor.

If it is required for several devices to be in operation at the same time, it is possible

to connect these to a switchboard containing distribution board, provided that the

permissible maximum rating is not exceeded.

Each station contains its own individual EMERGENCY STOP switch, which at first

reacts to its respective station only. It has to be clarified in advance, if a central

ROOM EMERGENCY STOP switch is required.

11 Electrical system

11.1 Power supply



Electrical system


The controller of the log area is located at the profile rack of the table.

No. Name Comment

1 BL20-GW-DPV1 Controller

2+3 BL20-2RFID-S Card for RFID sensors

4 24V Power Card for powers supply inputs

5-10 BL20-4DI-24VDC-P Cards for digital Inputs

11 24V Power Card for powers supply outputs

12-14 BL20-4DO-24VDC-0,5A-P Cards for digital outputs

S7 controller transport system example

11.2 Controller



Electrical system


The wiring within the station and the wiring to the other stations are explained in the

following.

11.3.1 I/O-Components

The operating strip, the moduls from the profil plate and the z-axis are pluggable

connected via I/O-terminals to the SM323 I/O-cards from the control.

So that a perfect communication can be ensured, the I/O interface is standardized.

The I/O terminal is at all work positions at the disposal.

I/O-Terminal

Technical data

Plug type IEEE 488 24 pins

Inputs 8

Outputs 8

Current consumption Max. 1A/PIN

Power supply 24 VDC

11.3 Wiring



Electrical system

Documents

Prolog Manual A005