Handling Instructor Rel C

Handling Station MPS 2000 Instructors Edition

© Festo Didactic GmbH & Co. • MPS

1

Order no.: Description:

Mechatronics Teachware Handling Station MPS 2000

Designation:

Instructors Edition

Status: Author:

Wolfgang Eckart, ADIRO Automatisierungstechnik GmbH

Graphics:

Wolfgang Eckart, Festo Didactic GmbH & Co

Layout:

Festo Didactic GmbH & Co

© Festo Didactic GmbH & Co., D-73770 Denkendorf, 2002 Internet: www.festo.com/didactic e-mail: [email protected] All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, or otherwise, without the prior written permission of Festo Didactic.

Table of Contents

Table of Contents ..................................................................................................... 1 Introduction ............................................................................................................. 3 What is Mechatronics ........................................................................................... 3 Project overview................................................................................................... 6 Commissioning......................................................................................................... 9 1.1

Analysis – Components identification ....................................................... 9

1.2

Analysis – Cable connections .................................................................. 11

1.3

Analysis – Input and Output adresses...................................................... 13

1.4

Analysis– Input and Output adresses expanded...................................... 17

1.5

Commissioning – Adjustment of the Station ............................................ 21

1.6

Commissioning – Adjustment of the Station expanded ............................ 23

1.7

Commissioning – Download Project and Test.......................................... 28

Programming ......................................................................................................... 33 2.1

Programming - Hardwareconfiguration .................................................... 33

2.2

Programming – Basics in Digital Technology – AND ................................. 46

2.3

Programming – Basics in Digital Technology – OR.................................... 61

2.4

Programming – Basics in Digital Technology – RS-Flip-Flop...................... 66

2.5

Programming – Basics in Digital Technology – AND NOT.......................... 71

2.6

Programming – Basics in Digital Technology – IDENTITY .......................... 74

2.7

Programming – Condition Call of a Program............................................. 76

2.8

Programming – Condition Call of a Program expanded............................. 79

2.9

Programming – On-Delay-Timer function ................................................. 88


1

Table of Contents

2.10

Programming – Off-Delay-Timer function ............................................. 93

2.11

Programming – Counter Down function................................................ 95

2.12

Programming – Programming of a Flashlight ........................................ 97

2.13

Programming –Programming of a Auto/Manu sequence ...................... 99

2.14

Programming – Move to Starting Position .......................................... 101

2.15

Programming – Expanded movement to Starting Position .................. 104

2.16

Project – Basics of I/O– communication ............................................. 109

2.17

Project – Test the I/O– communication .............................................. 113

2.18

Project – Material-flow through the FMS ........................................... 119

Trouble Shooting.................................................................................................. 135

2

3.1

Program – Trouble Shooting .................................................................. 135

3.2

Process – Trouble Shooting .................................................................. 164


Introduction

What is Mechatronics

Mechatronics is a comprehensive combination of Technologies and is mostly mentioned as a new way of thinking and learning and not as a “stand-alone” technology. The technological part of Mechatronics could be called Automation Technology.

MECHAnic

elecTRONic

MECHATRONIC

informatIC Structure of Mechatronics The structure of Mechatronical training is devided into three levels:

FMS-process: material- and signal flow

Totally integrated system Partly integrated systems

combination of: Mechanic,Electric Pneumatic,PLC single technology: Mechanic,Electric Pneumatic,PLC

Basics single technologies


3

Introduction

The Basic Training in the single technologies is another part of training. In the following you will see some examples of the different levels:

for totally integrated training

in the „Production Automation“ field of MECHATRONICS

Totally Integrated System

a combination of single technologies ...

... to a various amount of STATIONS

Partly Integrated Systems

electronics

pneumatics

sensorics

robotics

hydraulics

CAD/CNC

PLC

mechanics

Basic Technologies

4


Introduction

Basically in Automation and Mechatronics training, the contents should cover the following learning steps, or functions within a company: Commissioning:

Analyse a system, Installation&Commissioning

Programming:

Programming single Station, Communication with other Stations

Trouble Shooting: Programming Errors, Trouble Shooting in the Process

which are covered within the following projects. Furtheron this Teachware is based on the idea of a Flexible Manufacturing System – FMS, this means, this station should be and is connected to other stations, called Previous and Following Station within this Teachware.


5

Introduction

Project overview

The following table give you an overview about all projects within this documentation in the structure of: Commissioning:

Analysis (Analyse a system) and Commissioning (Installation&Commissioning)

Programming:

Programming (Programming single Station and Project (Communication with other Stations)

Trouble Shooting: Program (Programming Errors) and Process *(Trouble Shooting in the Process)

The table also mention the time which is necessary to work out the respective project. This time is based on experience with participants coming with no knowledge about the MPS-Stations and less knowledge about programming a Simatic PLC with STEP 7. *

Regarding the Process-Trouble Shooting, there is no big difference in time between the single troubles-based on experience we can say, that each trouble needs around 1,5 hour including the preparation and test of the error by the instructor and if the participants follow the three steps carefully and doing the documentation, which is very important. This structure allows you to put your specific workshop together according to your needs and your learning targets.

6


Introduction

Project overview Commissioning and Programming Learning Step

Designation

Project Description

Commissioning

Analysis

Commissioning

Analysis

Commissioning

Analysis

Commissioning

Analysis

Commissioning

Commissioning

Commissioning

Commissioning

Commissioning

Commissioning

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Project

Programming

Project

Programming

Project

Components identification: description of the function of some components used within the stations Cable connections in the system: define and identificate all cable connections in the FMS-system In-and Output adresses of the PLC: find out the hardwareadresses of in- and outputs in the technical docum. In-and Output adresses of the PLC expanded: find out the hardwareadresses of in- and outputs in the technical docum. Adjustment of the Station: check the adjustment all sensors and mechanical components Adjustment of the Station expanded: check the adjustment all sensors and mechanical components Download Project and Test: download all project-programs and test the function of the FMS-system Hardwareconfiguration of the PLC: define the existing Siemens S7-300 PLC-hardware with the software STEP 7 Basics in digital technology–AND: programming of the basic function AND Basics in digital technology–OR: programming of the basic function OR Basics in digital technology–RS-Flip-Flop: programming of the basic function RS-Flip-Flop Basics in digital technology–AND NOT: programming of the basic function AND NOT Basics in digital technology–IDENTITY: programming of the basic function IDENTITY Condition Call of a Program: activate a program in OB1 by a condition of the Control Panel Condition Call of a Program expanded: activate a program in OB1 by a condition of the Control Panel ON-Delay-Timer: programming of a ON-delay timer function using the Control Panel OFF-Delay-Timer: programming of a OFF-delay timer function using the Control Panel Counter down: programming of a Counter down function using the Control Panel Programming of one flashlight: programming a flashlight with 500 ms on/off as long as a button is pressed Programming of a Auto/Manu-sequence: program starts with Start-button/continues by Start or Auto/Manu-switch Move to Starting Position: edit a program to move to the starting (home) position automatically Move to Starting Position expanded: advanced movement to the starting (home) position automatically Theory Basics of I/O-communication: example of different in-/output communications using different controllers Test the I/O-communication: edit a program to test the I/O-communication at the stations Material flow through the FMS: one alu workpiece move through the whole FMS


Time [h]

Proj..

Page

1.1

9

1h 30min

1.2

11

30min

1.3

13

30min

1.4

17

1h 30min

1.5

21

1h

1.6

23

3h

1.7

28

1h

2.1

33

1h

2.2

46

1h 30min

2.3

61

1h

2.4

66

1h 30min

2.5

71

30min

2.6

74

30min

2.7

76

1h

2.8

79

1h

2.9

88

2h

2.10

93

1h

2.11

95

1h 30min

2.12

97

30min

2.13

99

2h

2.14

101

1h 30min

2.15

104

3h

2.16

109

1h

2.17

113

1h 30min

2.18

119

3h

7

Introduction

Project overview Trouble Shooting Designation

Project Description

Proj..

Trouble Shooting

Program

Error in Project 2.2

3.1

136

30min

Trouble Shooting

Program


3.1

138

30min

Trouble Shooting

Program


3.1

140

30min

Trouble Shooting

Program


3.1

142

30min

Trouble Shooting

Program


3.1

144

45min

Trouble Shooting

Program


3.1

146

30min

Trouble Shooting

Program


3.1

148

45min

Trouble Shooting

Program


3.1

150

45min

Trouble Shooting

Program


3.1

152

30min

Trouble Shooting

Program


3.1

154

45min

Trouble Shooting

Program


3.1

156

30min

Trouble Shooting

Program


3.1

158

1h

Trouble Shooting

Program

Error in additional Project

3.1

160

30min

Trouble Shooting

Process

Maintenance Trouble Shootingà14 Process-Errorsàtime for each approx.

3.2

162

1h 30min

8

Page

Time [h]

Learning Step


Commissioning

1.1

Analysis – Components identification

Please list up all the “sensors” and “actuators” shown in the picture below (1 – 3). Name the elements with identification in the wiring diagram/pneumatic plan and describe shortly their function generally (not the function within the system). Information Please use the technical manual-data sheets, pneumatic plan and wiring diagrams. Please refer to the examples (Ex.1 – Ex.3) mentioned below in the table of the execution work-sheet. Please follow the numbers (1 – 3) shown in the pictures below (Ex.1 is not shown in the graphics). Instructor: Show one example to the participants how to find an in- and output in the wiring diagrams and how to find the data sheet using the order number printed on the element itself. Show the participants at the station itself which components they have to identify. There are 4 different wiring diagrams for each station: the station itself (Station), the Control Panel (Panel), the PLC-board (PLC-board) and the Emergency-Stop (if available – optional). Please use one of the Examples Ex.2 or Ex. 3.

Planning Please plan your project within the whole team carefully. Use the technical manual and the real station to do this project. Please describe the function of the element in general, not within the signal- and materialflow of the station. To find the data-sheet of the elements, please see the list of components first and check the order no. printed on the element itself. The time to finish this project should be around 1,5 hours.


9

Commissioning

Execution/Documentation Please complete the list regarding the elements shown and numbered in the pictures above. No.

Name

Ident.

Description

Page #

Ex.1

Start-button

S1

Push button with light on the Control

no data sheet

Panel, normally open contact,

Panel: inputs

connected to a PLC-input Ex.2

Inductive switch, normally open

SME-8-S-LED-24

switch,

contact, activated by a magnet ring in

Station: inputs

inductive

the piston rod of the flat cylinder with

Station: pneumatic

non-rotating piston rod, send the

PLC-board: inputs

Proximity

2B2

information “piston rod of the cylinder is in up position” to the PLC-input Ex.3

Pneumatic

3A1

gripper

Double acting parallel gripper,

HGP-10-A

actuated by 2 parallel acting cylinders

Station: outputs

inside, with magent ring for end-

Station: pneumatic

position detection, gripper power 27 N

PLC-board: outputs

open and close

No.

Name

Ident.

Description

1

Retro

3B1

2

3

Page #

Retro reflective optical sensor, send out

SOEG-L-Q30-PA-S-2L

reflective

an infra-red signal and measure the

Station: inputs

sensor

reflection of the light.

PLC-board: inputs

Pneumatic flat

Flat cylinder with non-rotating piston

DGO-12-225-P-A

cylinder non-

rod, double acting, non-rotating by the

Station: outputs

rotating

form of the piston rod, with magnet ring

Station: pneumatic

for end-position detection

PLC-board: outputs

Light barrier sender

2A1

IP_N_FO

Infrared sender to the previous station,

SOEG-S-Q30-S-L

maximum range 6000 mm

Station: inputs PLC-board: inputs

10


Commissioning

1.2

Analysis – Cable connections

Please analyze the cable connections in your station and complete the drawing on the next page (Execution and Documentation). Information Please fill out all c in the graphic and draw the connections. Use the real station to check the connections. The standard station don´t have the Emergency Stop board, which is optional. Therefor all the following projects are defined without this board. Instructor: Please explain the structure of the PLC to the participants . Which adress have which module and which module have which function in controlling the process. Leave the cables all connected to help the participants. Show them also how to use the technical manual to find out the adress of the module. Please show the participants which steps and connections are necessary if the stations are coming with the Emergency Stop board and how to connect the Emergency switch buttons!!! Planning Please follow the explanations of the instructor first and then plan your activities step-by-step. Use the real station to find out all connections and identifications. Use also the technical documentation. The time to finish this project should be around 0,5 hours.


11

Commissioning

Execution/Documentation

12


Commissioning

1.3

Analysis – Input and Output adresses

Please complete the below mentioned list of input- and outputadresses of the PLC. Please define your own symbol adress using max. 8 characters. Information To find out the adresses, please refer to the technical manual-wiring diagram for the station and the Control Panel. The inputs can also be checked directly at the PLCLED´s, the outputs not without a program. To move pneumatic actuators, please switch off the air-pressure and move them manually by hand. Please be very careful, move the actuators back before switching on the air-pressure again. Some pneumatic and the electrical actuators can not be moved in this way-the pneumatic components can be activated by the manual detection button on the valve (see picture) Instructor:show the participants how to find out an input and an output using the wiring diagrams. Show them why some actuators can not be moved by hand even without air- and power supply (DC-motors and 5/3-way valves) using the pneumatic plan to explain.

Example: press 1 = vacuum is on, press 2 = vacuum is off


13

Commissioning

Planning Please plan your activities within your team. Check first, which actuator could be moved by hand and which not-use the technical documentation-pneumatic plan. Check the inputs in the wiring diagram and at the PLC. The time to finish this project should be around 0,5 hour.

14


Commissioning

Execution/Documentation Please complete the list of the inputs and outputs of your station. I/O Station Adress

Symbol

Ident.

Description

I0.0

Part_av

Part_AV

Workpiece is available

I0.1

Han_prev

1B1

Handling at previous station

I0.2

Han_foll

1B2

Handling at following station

I0.3

Han_sort

1B3

Handling at sorting position

I0.4

Lift_dow

2B1

Lifting cylinder with gripper is down

I0.5

Lift _up

2B2

Lifting cylinder with gripper is up

I0.6

Sen_mat

3B1

Material detection signal = 0 = black

I0.7

Follow

IP_FL

Light barrier to the following station

Q0.0

Handprev

1Y1

Solenoid of handling cyl.to previous station

Q0.1

Handfoll

1Y2

Solenoid of handling cyl.to following station

Q0.2

Lifting

2Y1

Solenoid of the lifting cylinder with gripper

Q0.3

Gripper

3Y1

Solenoid of the gripper = 1 = open

Q0.7

Previous

IP_N_FO Light barrier to the previous station

I/O Control Panel Adress

Symbol

Ident.

Description

I1.0

START

S1

Start button

I1.1

STOP

S2

Stop button

I1.2

AUTOMAN

S3

Switch automatic and manual cycle

I1.3

RESET

S4

Reset button

I1.5

EMERGEN

S1

Emergency stop switch-reset with Quit-button

Q1.0

L_START

H1

Light inside the Start button

Q1.1

L_RESET

H2

Light inside the Reset button

Q1.2

L_SPEC1

H3

Light no. 1 special function

Q1.3

L_SPEC2

H4



15

Commissioning

I/O Communication

16

Adress

Symbol

Ident.

Description

I1.4

CI1_Prev

Input comm. from Q1.6 Previous Station

I1.6

CI1_Foll

Input comm. from Q1.4 Following Station

I1.7

CI2_Foll


Q1.4

CQ1_Prev

Output comm. to I1.6 Previous Station

Q1.5

CQ2_Prev


Q1.6

CQ1_Foll

Output comm. to I1.4 Following Station


Commissioning

1.4

Analysis– Input and Output adresses expanded

Please complete the below mentioned list of input- and outputadresses of the PLC. Please define your own symbol adress using max. 8 characters. Information To find out the adresses please use the technical manual-wiring diagram for the station and the Control Panel. The inputs can also be checked directly at the PLCLED´s, the outputs not without a program. To move pneumatic actuators, please switch off the air-pressure and move them manually by hand. Please be very careful, move the actuators back before switching on the air-pressure again. Some pneumatic and the electrical actuators can not be moved in this way-the pneumatic components can be activated by the manual detection button on the valve (see picture) Instructor:show the participants how to find out an input and an output using the wiring diagrams. Show them why some actuators can not be moved by hand even without air- and power supply (DC-motors and 5/3-way valves) using the pneumatic plan to explain. Show them also how to find out the communication inand outputs.

Example: press 1 = vacuum is on, press 2 = vacuum is off


17

Commissioning

Planning Please plan your activities within your team. Check first, which actuator could be moved by hand and which not-use the technical documentation-pneumatic plan. Check the inputs in the wiring diagram and at the PLC. The time to finish this project should be around 1,5 hour.

18


Commissioning

Execution/Documentation Please complete the list of the inputs and outputs of your station. I/O Station Adress

Symbol

Ident.

Description

I0.0

Part_av

Part_AV


I0.1

Han_prev

1B1


I0.2

Han_foll

1B2


I0.3

Han_sort

1B3


I0.4

Lift_dow

2B1


I0.5

Lift _up

2B2


I0.6

Sen_mat

3B1


I0.7

Follow

IP_FL


Q0.0

Handprev

1Y1


Q0.1

Handfoll

1Y2


Q0.2

Lifting

2Y1


Q0.3

Gripper

3Y1


Q0.7

Previous


I/O Control Panel Adress

Symbol

Ident.

Description

I1.0

START

S1

Start button

I1.1

STOP

S2

Stop button

I1.2

AUTOMAN

S3

Switch automatic and manual cycle

I1.3

RESET

S4

Reset button

I1.5

EMERGEN

S1

Emergency stop switch-reset with Quit-button

Q1.0

L_START

H1

Light inside the Start button

Q1.1

L_RESET

H2

Light inside the Reset button

Q1.2

L_SPEC1

H3


Q1.3

L_SPEC2

H4



19

Commissioning

I/O Communication

20

Adress

Symbol

Ident.

Description

I1.4

CI1_Prev


I1.6

CI1_Foll


I1.7

CI2_Foll


Q1.4

CQ1_Prev


Q1.5

CQ2_Prev


Q1.6

CQ1_Foll



Commissioning

1.5

Commissioning – Adjustment of the Station

Please check the adjustment of all sensors and of the mechanical components of your station to prepare the test of the whole process. Information To find out the function and location of the sensors, please use the technical manual. The inputs can also be checked directly at the PLC-LED´s. To move pneumatic actuators, please switch off the air-pressure and move them manually by hand. Please be very careful, move the actuators back before switching on the airpressure again. Some pneumatic and the electrical actuators can not be moved in this way-the pneumatic components can be activated by the manual detection button on the valve (see picture) Instructor:show the participants how to find out an input and an output using the wiring diagrams. Show them why some actuators can not be moved by hand even without air- and power supply (DC-motors and 5/3-way valves) using the pneumatic plan to explain. Show them an example how to adjust a sensor to define the back or front position of a cylinder. Provide the necessary tools. Deadjust the following sensors and mechanical components (bold) I/O Station Adress

Symbol

Ident.

Description

I0.0

Part_av

Part_AV Workpiece is available

I0.1

Han_prev

1B1


I0.2

Han_foll

1B2


I0.3

Han_sort

1B3


I0.4

Lift_dow

2B1


I0.5

Lift _up

2B2


I0.6

Sen_mat

3B1


I0.7

Follow

IP_FL


Q0.0

Handprev

1Y1


Q0.1

Handfoll

1Y2


Q0.2

Lifting

2Y1


Q0.3

Gripper

3Y1


Q0.7

Previous


Deadjust the workpiece mounting so that the gripper is not able to pick up the workpiece centred and close the one-way-flow control valve of the lifting cylinder to move up.


21

Commissioning

Planning Please plan your activities within your team. Check first, which actuator could be moved by hand and which not-use the technical documentation-pneumatic plan. Check the inputs in the wiring diagram and at the PLC. Check the adjustment of the sensors first, then the mechanical elements. The time to finish this project should be around 1,0 hour. Execution/Documentation Write down the single steps and all useful informations. Write down your single steps you did to proceed. Use the table to proceed. I/O Station

22

Adress

Symbol

Ident.

Description

Check

I0.0

Part_av

Part_AV


I0.1

Han_prev

1B1


I0.2

Han_foll

1B2


I0.3

Han_sort

1B3


I0.4

Lift_dow

2B1


I0.5

Lift _up

2B2


I0.6

Sen_mat

3B1


I0.7

Follow

IP_FL


Q0.0

Handprev

1Y1

Solenoid of handling cyl.to prev.station

Q0.1

Handfoll

1Y2

Solenoid of handling cyl.to foll.station

Q0.2

Lifting

2Y1

Solenoid of the lifting cyl.with gripper

Q0.3

Gripper

3Y1


Q0.7

Previous



Commissioning

1.6

Commissioning – Adjustment of the Station expanded

Please check the adjustment of all sensors, the mechanical components and the pneumatical components of your station to prepare the test of the whole process. Check also the cable connectionsand the power- and air-supply. Information To find out the function and location of the sensors and pneumatical components please use the technical documentation. The inputs can also be checked directly at the PLC-LED´s. To move pneumatic actuators, please switch off the air-pressure and move them manually by hand. Please be very careful, move the actuators back before switching on the air-pressure again. Some pneumatic and the electrical actuators can not be moved in this way-the pneumatic components can be activated by the manual detection button on the valve (see picture) Instructor:show the participants how to find out an input and an output using the wiring diagrams. Show them why some actuators can not be moved by hand even without air- and power supply (DC-motors and 5/3-way valves) using the pneumatic plan to explain. Show them an example how to adjust a sensor to define the back or front position of a cylinder and how to adjust the speed of a pneumatical actuator. Provide the necessary tools. Deadjust the following sensors and mechanical components (bold)


23

Commissioning

I/O Station Adress

Symbol

Ident.

I0.0

Part_av

Part_AV Workpiece is available

I0.1

Han_prev

1B1


I0.2

Han_foll

1B2


I0.3

Han_sort

1B3


I0.4

Lift_dow

2B1


I0.5

Lift _up

2B2


I0.6

Sen_mat

3B1


I0.7

Follow

IP_FL


Q0.0

Handprev

1Y1


Q0.1

Handfoll

1Y2


Q0.2

Lifting

2Y1


Q0.3

Gripper

3Y1


Q0.7

Previous


Adress

Symbol

I1.4

CI1_Prev


I1.6

CI1_Foll


I1.7

CI2_Foll


Q1.4

CQ1_Prev


Q1.5

CQ2_Prev


Q1.6

CQ1_Foll


Ident.

Description

Description

Q0.2 à Deadjust the workpiece mounting so that the gripper is not able to pick up the workpiece centred and close the one-way-flow control valve of the lifting cylinder to move up. Disconnect the 4 mm cluster plug cables of the communication to the previous and the following station. Disconnect the power- and air supply and disconnect the station from the other following station. Disconnect the cable connections between the station and the PLC-board and remove the whole board from the trolley. Remove also the control panel from the trolley.

24


Commissioning

Work out together with the participants the general steps of Installation.The conditions for this example shall be: • the PLC-board is removed • no power supply connection, no air-pressure supply • the Control Panel is removed

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

check the adjustment of mechanical components check the adjustment of mechanical actuators holder check the PLC-modules assemble removed components (like PLC-board and Control Panel) cable connections (PLC-board, Control Panel, communication) connect all power supplies check the adjustment of sensor holders check the adjustment of sensors in the holders check the adjustment of sensitivity of sensor tubing connections connect all air-pressure supplies (careful! turn pressure down before) check the adjustment of the speed of pneumatic actuators connect the stations together check the mechanical position of hand over to the next station communication connection

Planning Please plan your activities within your team. Check first, which actuator could be moved by hand and which not-use the technical documentation-pneumatic plan. Check the inputs in the wiring diagram and at the PLC. Check the adjustment of the sensors first, then the mechanical and pneumatical elements and. The time to finish this project should be around 3,0 hour.


25

Commissioning

Execution/Documentation Write down the single steps and all useful informations. Write down your single steps you did to proceed. Use the tables to proceed. I/O Station Adress

Symbol

Ident.

Description

Check

I0.0

Part_av

Part_AV


I0.1

Han_prev

1B1


I0.2

Han_foll

1B2


I0.3

Han_sort

1B3


I0.4

Lift_dow

2B1


I0.5

Lift _up

2B2


I0.6

Sen_mat

3B1


I0.7

Follow

IP_FL


Q0.0

Handprev

1Y1

Solenoid of handling cyl.to prev.station

Q0.1

Handfoll

1Y2

Solenoid of handling cyl.to foll.station

Q0.2

Lifting

2Y1

Solenoid of the lifting cyl.with gripper

Q0.3

Gripper

3Y1


Q0.7

Previous


I/O Communication

26

Adress

Symbol

Ident.

Description

Check

I1.4

CI1_Prev


I1.6

CI1_Foll


I1.7

CI2_Foll


Q1.4

CQ1_Prev


Q1.5

CQ2_Prev


Q1.6

CQ1_Foll



Commissioning

Step No.:


Description

1

check the adjustment of mechanical components

2

check the adjustment of mechanical actuators holder

3

check the PLC-modules

4

assemble removed components (PLC-board/Control Panel)

5

cable connections (PLC-board, Control Panel, communication)

6

connect all power supplies

7

check the adjustment of sensor holders

8

check the adjustment of sensors in the holders

9

check the adjustment of sensitivity of sensor

10

tubing connections

11

connect all air-pressure supplies (careful! turn pressure down)

12

check the adjustment of the speed of pneumatic actuators

13

connect the stations together

14

check the mechanical position of hand over to the next station

15

communication connection

Check

27

Commissioning

1.7

Commissioning – Download Project and Test

Please download the full project into the PLC and test the full process. Information Please make sure that the PC is connected to the PLC with the communication cable, the power supply of the station is on, air-pressure of around 5 bar is available at each station, the emergency switch is deactivated (if available) and the CPU-switch is in STOP position. Make sure that the PLC memory is empty (delete). Instructor: Show how to delete the contents of a CPU using the switch of the CPU. Let all the participants try it several times. Explain them where to find the project and what the project name is. Explain them step-by-step how to download a project to the PLC. Develop the process sequence on the white board first this means, what is the process and how to start it. Which are the Control Panel functions. Tell the participants, in which subdirectory they are able to find the programs à in the following screen shots, the project is located in: C:\SIEMENS\STEP7\MPSVERSC Basically all screen shots and PLC-projects are based on the software STEP 7 Version 5.1 – other versions may be a little bit different, but the used functions and screen shots within the following projects are mostly the same!!!! Planning Please follow the description of the in instructor carefully step-by-step. Use the NOTICE field to write down the single steps to proceed. The time to finish this project should be around 1,0 hours.

28


Commissioning

Execution/Documentation Follow the single steps of the instructor. Write down the single steps and all useful informations into the field NOTICE. Write down your single steps you did to proceed: 1. Press Emergency switch à reset all outputs and memories (if available, if not press Stop-button once) 2. Check the air-pressure à = 5 bar 3. Check cable connection à plug should be locked 4. Release Emergency switch 5. Station in home position and workpiece in the feeder à Reset light is on 6. Press Start-button à light Start is on and process start 5. 6. 7. 8.

Station is not in home position à Reset light is off Press Reset-button à movement of actuators to home position Station in home position and workpiece in the feeder à Reset light is on Press Start-button à light Start is on and process start

The process can be interrupted by pressing Emergency switch (if available) or Stopbutton at each time à restart with step 4 with Emergency switch or step 5 without. How to open and download the project of the full FMS-project is shown on the following:


29

Commissioning

File à Open à Browse à (select subdirectory – here C:\Siemens\Step7) MPSVERSC à OK (left mouse button)

30


Commissioning

(click on the right project – example project 1VE_KFA for the Distribution Station – refer to the list below for other stations) PLC à Download à (follow the instructions on the screen to download the project – after download is finish, switch the CPUswitch to RUN and test the program) 1VE_KFA

Distribution Station

2PR_KFA

Testing Station

3BE_KFA

Processing Station

4PA_KFA

Handling (PickAlfa)

5PU_KFA

Buffer Station

6MO_KFA

Assembly Station

7SO_KFA

Sorting Station

8HY_KFA

Hydraulic Station


31

Commissioning

32


Programming

2.1

Programming Hardwareconfigura tion

Please define the PLC-hardware used within your station with the STEP 7 software. After the configuration, please download it into the PLC. Information Please make sure that the PC is connected to the PLC with the communication cable, the power supply of the station is on, the emergency switch is deactivated and the CPU-switch is in STOP position. Make sure that the PLC memory is empty (delete). Use the screen shots (execution) to proceed. Open a new project and name it P2_01. It´s not necessary to add the station name into the hardwareconfiguration name, because the configuration is the same for all stations. Instructor: Show how to delete the contents of a CPU using the switch of the CPU. Let all the participants try it several times. Explain them where to find the name of the PLC-modules (on the top of the module, for example SM 323) and the ordernumber (6ES7……..) and explain why this order-number is so important for the hardwareconfiguration. Explain also what a Clock Memory is and what Retentive Memories are and why it´s better to switch them to 0. Planning Please follow the description (screen shots) carefully step by step. Please make sure, that every member of your team did the hardwareconfiguration at least once. The time to finish this project should be around 1,0 hours.


33

Programming

Execution Screen shots of the hardwareconfiguration, the bold words are commands to click on, the ( ) are only comments (ENTER) means click left mouse button once or press ENTER, (double click) means double click the left mouse button:

File à New à (type Name: P2_01) à OK

34


Programming

Insert à Station à SIMATIC 300 Station


35

Programming

+ P2_01 à SIMATIC 300(1) à Hardware (double click)

36


Programming

+ SIMATIC 300 à + RACK-300 à Rail à (double click)


37

Programming

- RACK 300 à + CPU-300 à + CPU 314 à + 6ES7 314-1AE04-0AB0 (depends on the CPU you use – check the order no. on the front left below corner of the CPU) à V1.2 (depends on the CPU you use – open the flap of the CPU and you will find the right version number on the left below corner) à (double click)

38


Programming

CPU 314 (at the Slot 2 – double click) à Cycle/Clock Memory à Clock Memory à 100 (Memory Byte – free definition)


39

Programming

Retentive Memory à 0 (Number of Memory Bytes Starting with MB0) à 0 (Number of S7 Timers Starting with T0) à 0 Number of S7 Counters Starting with C0) à OK

40


Programming

- CPU-300 à + SM-300 à + DI/DO-300 à SM 323 DI16/DO16x24V/0,5A (depends on the input/output module you use – refer to the left below corner of the module to find the right number) (double click)


41

Programming

- SIMATIC 300 à Station à Save and Compile

42


Programming

PLC à Download (follow the instructions on the screen to download the hardwareconfiguration)


43

Programming

(after download without an error message switch the CPU to RUN - no red light SF - switch the CPU to STOP again) Station à Exit

44


Programming

Controll If there will be no error message after saving and compiling your hardwareconfiguration and no error message while or after downloading, the hardwareconfiguration have been done properly. Change the switch on the CPU to RUN-position-if there is no read light SF the configuration was successful and then change the swithc to STOP again. Documentation Please add your own comments to the screen shots.


45

Programming

2.2

Programming – Basics in Digital Technology – AND

Please edit the PLC-program concerning the following description: as long as a Start-button AND a Reset-button are pressed, the piston rod of the cylinder move. The cylinder is actuated by a 5/2-way single solenoid valve. Please find out in the pneumatic plan which cylinder/actuator you gonna use. Information Use FC5 to edit the program. Open a new project and name it P2_02 (see screen shots in the part Planning. We didn´t close the project P2_01, because we have to copy the Hardwareconfiguration from this project to the new one. Use the hardwareadresses (see list in Project 1.3) to edit the program. The programming language in FC1 should be FBD (Function Block Diagram), in OB1 STL (Statement List). FC1 starts unconditional (UC). Instructor: Please explain the programming structure of a PLC (S5 or S7) with OB1, FC, FB, SFB, SFC. Explain also the two ways to call a program (Function) from OB1 (UC and CC) Work out the Truth table, Wiring diagram, Logic plan and Stepping diagram together with the participants. Explain that the basics on the following pages are principal-functions (because the output is the Start-light H1). Explain also the two different possibilities to structure a project – seen on the next page. Show the participants how to copy a hardwareconfiguration from another project. Explain to the participants, that the meaning of "cylinder move" is depending on the hardware and onto the connection to the responding valve. "cylinder move" means, from the front to the back position if the piston rod starting condition is the front position and to the front position if the piston rod starting condition is the back position!!!!

46


Programming

There are two possibilities to structure a project à Struc01 shows a structure, where four Programs are parallel to the Station SIMATIC 300(1) à this structure is used for education, because there are mostly more than only one different exercise (Programs) for one station. Struc02 shows a typical industrial structure, because there is mostly only one Program for one station or application. The first projects within this teachware are based on Struc01, later we will change it to the Struc02 to see and learn both different possibilities.


47

Programming

48


Programming

In the following please find some important informations regarding pneumatic actuators and their triggering. This informations are basically. Instructor: In the following exercises, pneumatic working elements are used. Therefore, a short introduction in these technological features are necessary. Double-acting cylinders with the ability to work at forward- and backward movement are pneumatic working elements, which are often used. These cylinders are mostly triggered by 5/2-way valves. Explain the following three graphics. • 5 = number of connections (1, 3, 4, 2 and 5) • 2 = 2 switching positions (2 rectangles) The connections have the following functions: 1(P) = air connection (supply) 2(B) = output B for backward stroke 3(S) = connection exhaust air of forward stroke 4(A) = output A for forward stroke 5(S) = connection exhaust air of backward stroke In the following drawing you can find letters in brackets behind the standardized designation of the connections (1, 3, 4, 2 and 5). These letters are former designations, one can still find them on old elements.

Single solenoid

4(A)

Double solenoid

2(B)

14 y1

4(A) 14

5(S)

3(R) 1(P)

y2

2(B) 12

5(S)

3(R) y3 1(P)

Activation of single/double solenoid valve:


49

Programming

4(A)

2(B)

14 y1

5(S)

power (24VDC) connected to Y1

3(R) 1(P)

4(A)

2(B)

14 y1 5(S)

3(R) 1(P)

Activation of a single solenoid valve:

4(A) 2(B) short 14 power signal y2 5(S) 3(R) (24VDC) 1(P) connected to y2

4(A)

12 14 y3

y2

2(B)

short power signal 3(R) y3 5(S) (24VDC) 1(P) connected to y3 12

Activation of a double solenoid valve:

50


Programming

Planning Please plan your project step by step first within the group. Use the list of inputs and outputs of the Project 1.3. Work out the informations of truth table, wiring diagram, logic plan and stepping diagram first together with the Instructor. Before programming, don´t forget to delete the contents of the PLC using the CPU-switch. The time to finish this project should be around 1,5 hour including theory.

File à New à (type name P2_02) à OK


51

Programming

SIMATIC 300(1) (click on station of the project P2_01 with the right mouse button) à Copy

52


Programming

P2_02 (right mouse button on the project P2_02) à Paste


53

Programming

X (close the project P2_01)

54


Programming

P2_02 à Insert à Program à S7 Program


55

Programming

+ S7 Program (2) à Blocks à Insert à S7 Block à Function

56


Programming

FBD (change programming language of FC1 to FBD = Function Block Diagram) à OK


57

Programming

Execution/Documentation Edit the Organisation Block 1 first by double click on OB1. Program OB1:

(After editing) Edit à Save à (no error message) Edit à Exit This procedure is always the same after editing a program à it´s not mentioned anymore!!!

58


Programming

Edit the the application within the Function 1 by double click on FC1. Program FC1:


59

Programming

Controll After editing the project download it to the CPU. Test the function according the project description.

Block à PLC à Download (follow the instructions on the screen) This procedure to download a project is always the same after editing a program à it´s not mentioned anymore!!!

60


Programming

2.3

Programming – Basics in Digital Technology – OR

Please edit the PLC-program concerning the following description: as long as a Start-button OR a Auto/Manu-switch is activated, the piston rod of the cylinder move. The cylinder is actuated by a 5/2-way single solenoid valve. Information Use FC5 to edit the program. Open a new project and name it P2_03. Please copy the hardwareconfiguration from P2_01 or P2_02. Please use the symbol adresses shown in the list of inputs and outputs of Project 1.3 to edit the program. The programming language for FC1 should be FBD, for OB1 STL. The FC5 shall starts unconditional. The following screen shows the project structure and the symbol editor. Instructor: Work out the basics of an OR, shown on the next page together with the participants. Show them how to use the symbol editor.


61

Programming

(after insertation of the SIMATIC 300(1) station, copy of the Hardwareconfiguration, insertation of a S7 Program(2) please open the Symbol Editor) + P2_03 à S7 Program(2) à Symbols (double click) à (edit the symbols, the adresses and the comments and save the file) Symbol Table à Save à X (close the window of the Symbol Editor)

62


Programming


63

Programming

Planning Please plan your project step by step first within the group. Use the list of inputs and outputs of the Project 1.3. Work out the informations of truth table, wiring diagram, logic plan and stepping diagram first together with the Instructor. Before programming, don´t forget to delete the contents of the PLC using the CPU-switch again. Insert the application function FC5 to the Blocks, like described within the Project 2.2 and edit the OB1 and the FC5. After editing, please download the Blocks to the CPU and test the program. The time to finish this project should be around 1,0 hour including theory. Execution/Documentation Program OB1:

64


Programming

Program FC5:

If you click the right mouse button on an input or output and click on Insert Symbol., you will get a list of all defined inputs and outputs within the Symbol Editor. Controll Edit the project and download it. Test the function according the project description.


65

Programming

2.4

Programming – Basics in Digital Technology – RSFlip-Flop

Please edit the PLC-program concerning the following description: if a Start-button is pressed shortly, the piston rod of the cylinder with single solenoid shall move as long as a Reset button is pressed shortly. If the Start- and the Reset button are pressed at the same time, the piston rod shall not move out. Information Use FC1 to edit the program. Open a new project and name it P2_04. Please copy the hardwareconfiguration and the OB1 from the project before. Please use symbol adresses. How to edit the symbol editor was shown in the project P2_03. The programming language should be FBD. Instructor: Work out the basics, shown on the next page together with the participants. Explain the differences of reset- and set dominant. Show how to copy an OB1 into a new project. Show them how to use the hardwarecatalog (Program elements) to edit in FBD (see screen next pages). Show the participants how to watch the function online on the computer.

66


Programming


67

Programming

Planning Please plan your project step by step first within the group. Use the list of inputs and outputs of the Project 1.3. Work out the informations of truth table, wiring diagram, logic plan and stepping diagram first together with the Instructors. Before programming, don´t forget to delete the contents of the PLC using the CPU-switch. The time to finish this project should be around 1,5 hour including theory. Execution/Documentation Program OB1

68


Programming

Program FC1


69

Programming

Controll Edit the project and download it. See the function of the project online on your computer (see screen). Test the function according the project description.

(click on the glasses to switch to online-mode, after finish, please switch the onlinemode off and close the window with Edit à Exit)

70


Programming

2.5

Programming – Basics in Digital Technology – AND NOT

Please edit the PLC-program concerning the following description: as long as a Start-button is pressed AND a Auto/Manu-switch is NOT activated, the piston rod of the cylinder with single solenoid shall move. Information Use FC10 to edit the program. Open a new project and name it P2_05. Please copy the hardwareconfiguration from the project before. Please use symbol adresses. The programming language for FC10 should be FBD, for OB1 STL. The FC10 shall start unconditional. Work out the Truth Table together with the instructor first. Instructor: Please work out the Truth table together with the participants. Show how to negate an input in the program with FBD. Explain that within the program they shall use the cylinder with single solenoid valve not the light H1.

Planning Please plan your project step by step first within the group. The time to finish this project should be around 0,5 hour.


71

Programming

Execution/Documentation Program OB1

72


Programming

Program FC10

Controll Edit the project and download it. Test the function according the project description. Watch FC10 with the online-function (description see Project 2.4).


73

Programming

2.6

Programming – Basics in Digital Technology – IDENTITY

Please edit the PLC-program concerning the following Truth table. Reduce the logic as much as possible. Use the Start-button (S) and the Reset-button (R) and the cylinder with single solenoid valve (H1).

Information Use FC1 to edit the program. Open a new project and name it P2_06. Please open the Project 2.4 (P2_04) again and copy all parts you need. Please use symbol adresses. The programming language for FC1 and for OB1 should be STL. The FC1 shall start unconditional. Instructor: Please tell the participants, that only one logic module is needed for this project. Planning Please plan your project step by step first within the group. The time to finish this project should be around 0,5 hour.

74


Programming

Execution/Documentation Program FC1, OB1 is the same than in the Project 2.4

Controll Edit the project and download it. Test the function according the project description. Watch FC1 with the online-function (description see Project 2.4).


75

Programming

2.7

Programming – Condition Call of a Program

After a short actuation of a Start-button, the piston rod of the cylinder with single solenoid shall move as long as a Reset- or a Stop-button is pressed shortly. The program shall be activated by the Auto/Manu switch, the program FC8 is not running if the Auto/Manu switch is off. Information Use the project before as a base and copy all parts from this project you need. Use FC8 to edit the program. Open a new project and name it P2_07. Please use symbol adresses. The programming language for FC8 is FBD, for OB1 STL. Instructor: Explain how to rename a function (right mouse button à Rename). Planning Please plan your project step by step first within the team. Discuss the differences to call a function (FC) with and without a condition. The command for conditional call is CC. Before the action of CC, you have to edit a condition-which condition is this? The time to finish this project should be around 1,0 hour.

76


Programming

Execution/Documentation Program OB1


77

Programming

Program FC8

Controll Edit the project and download it. Test the function according the project description. Watch the function of the FC with the online-function. This controll step will be the same for all the following projects, so it´s not mentioned in each project anymore.

78


Programming

2.8

Programming – Condition Call of a Program expanded

Expand the Project 2.7 (P2_07) after a short actuation of a Start-button, the piston rod of the cylinder with solenoid valve shall move as long as a Reset- or a Stop-button is pressed shortly. The program shall be activated by the Auto/Manu switch, this means, the program is not running if the switch is off with the additional function à the piston rod move to the starting condition if the Auto/Manu switch is off. Information Use the Project 2.7 (P2_07) as a base and save it with a new name P2_08 with Edit à Save as. See the following screen shots "Save an open project with a new name". Use FC1 to edit the program. Please use symbol adresses. The programming language for FC1 should be FBD, for OB1 STL. We also use another structure of the project. Please see the screen shot "New structure of the project" and follow the structure for all following projects. Also please switch the CPU to the RUN-P-mode. Within this mode you can delete, download and warmstart the CPU from the computer. Please follow the instructor step by step how to do it. Instructor: Explain the differences between this and the project-structure before. Refer to the explanations in Project 2.2. Explain the difference between the RUNand the RUN-P-mode at the CPU-switch. Show the participants how to delete the CPU, download and restart it step by step.


79

Programming

Save an open project with a new name:

File à Save As à P2_08 (type in the new name) à OK

80


Programming

Copy the contents of the S7 Program(2):

S7 Program(2) (right mouse button) à Copy


81

Programming

CPU 314 (right mouse button) à Paste

82


Programming

Delete the S7 Program(2)

S7 Program(2) (right mouse button) à Delete (follow the instructions on the screen)


83

Programming

Rename FC8 to FC1

+ CPU 314 à + S7 Program(2) à Blocks à FC8 (right mouse button) à Rename à (rename FC8 to FC1) à OK

84


Programming

New structure of the project:


85

Programming

Planning Please plan your project step by step first within the team. Before programming, don´t forget to delete the contents of the PLC from the computer. Edit the project (programs) on a sheet of paper first. The time to finish this project should be around 1,0 hour. Execution/Documentation Program OB1

86


Programming

Program FC1


87

Programming

2.9

Programming – On-Delay-Timer function

If a Start-button is pressed and hold, the Start-light (H1) shall be on after 5,0 seconds and stay on until the button is pressed. The timer is only running while the Start-button is pressed. If the Start-button will be released before 5 seconds, the timer start new. Information Use FC1 to edit the program. Save the actual Project as a new project named P2_09. Please use symbol adresses. The programming language for FC1 should be FBD, for OB1 STL. Use the Hardwarecatalog (Program elements) to edit the program in FBD (see screens "Open the Hardwarecatalog") and use the help-function to get further informations (see the screen shots "Help function for an On-Delay-Timer"). Use Timer 1 for this project. Instructor: Discuss about the different timer-functions and show how to open and use the help-function in the Hardwarecatalog (Program element).

88


Programming

Open the Hardwarecatalog: (if the Hardwarecatalog is not open (window in the right corner “Program elements”), please open it in the FC1)

View à Catalog à (the window Program elements opens)


89

Programming

Help function for an On-Delay-Timer

+ Timers à S_ODT à (click on the ? and you see a description of the function)

90


Programming

Planning Please plan your project step by step first within the team. Check out the function of all timers with the help function and choose the right timer for your project. May be it´s helpful, to print the help-functions of the timers for further projects. Edit on a sheet of paper first. The time to finish this project should be around 2,0 hour including theory and print out of the different timers. Execution/Documentation Program OB1


91

Programming

Program FC1

92


Programming

2.10

Programming – Off-Delay-Timer function

If a Start-button is pressed, the Start-light (H1) shall be on as long as the Startbutton is pressed. If you release the Start-button, the light will be on for another 3 seconds. Information Use FC1 to edit the programs. Please use symbol adresses. The programming language for FC1 should be FBD, for OB1 STL. Use Timer 2 for this project. Planning Please plan your project step by step first within the team. Check out the function of all timers and choose the right timer for your project. Edit on a sheet of paper first. The time to finish this project should be around 1,0 hour.


93

Programming

Execution/Documentation Program FC1, the program OB1 is the same than for the project before

94


Programming

2.11

Programming – Counter Down function

If a Start-button is pressed, the piston rod of the cylinder move until reaching the sensor for the front/back position depending on the hardware and then move back to starting condition automatically. After starting 5 times, the Start-light must be on and the piston rod can not move again. Set the counter by pressing the Reset-button once. Information Use FC1 to edit the programs. Please use symbol adresses. The programming language for FC1 should be FBD, for OB1 STL. Use Counter 1 for this project. Instructor: Explain the differences to count up or count down from the output point of view. Explain the function of the edge memory. Explain why it´s better to use it for this project à some contacts shetter or bounce à the counting would not be correct. Planning Please plan your project step by step first within the team. Check out the function of all counters as shown for the timers in the Project 2.9 and choose the right counter for your project. Edit on a sheet of paper first. The time to finish this project should be around 1,5 hour including theory and print out of the different counters.


95

Programming


The logic module P (M10.0) is an edge memory this means, even you hold Startbutton down, only a short pulse will come through to the input. Some contact shatter or bounce even you press them only once.

96


Programming

2.12

Programming – Programming of a Flashlight

As long as a Start-button is pressed, a Start-light (H1) flash with 500 ms on and 500 ms off. The program of FC1 should be done with only one Network. Information Use FC1 to edit the programs. Please use symbol adresses. The programming language for FC1 should be FBD, for OB1 STL. There is a Memorybyte (Clock Memory) defined within the hardwareconfiguration which automatically flash with different frequences or different time periods. Please see the following time periods for the 8 Bits of the Memorybyte 100 (100 is free defined within the Hardwareconfiguration). A time period is the time the Memory is on and the time the Memory is off: M100.0 = 0,1 sec. M100.1 = 0,2 sec. M100.2 = 0,4 sec. M100.3 = 0,5 sec. M100.4 = 0,8 sec. M100.5 = 1,0 sec. M100.6 = 1,6 sec. M100.7 = 2,0 sec Instructor: Show the Clock Memory and the help-function within the hardwareconfiguration and explain that the adress of the MB 100 is free defined à could be changed. Planning Please plan your project step by step first within the team. Check out the hardwareconfiguration in Project 2.1 again how to define and activate the Clock Memory . The time to finish this project should be around 0,5 hour.


97

Programming


98


Programming

2.13

Programming – Programming of a Auto/Manu sequence

The starting condition for this project is to press the Start-button shortly. After the Start-button was pressed shortly, the Start-light is on for 1 second. After the Startlight is off, the Reset-light is on for 3 seconds à cycle end. To newstart the cycle, either press Start-button again (Manu-cycle), or switch the Auto/Manu-switch to on. Information Use FC1 to edit the program. Please use symbol adresses. The programming language for FC1 should be FBD, for OB1 STL. The first start of the cycle must be by pressing Start-button, not with Auto/Manu-switch. Instructor: Explain very clearly that the first cycle, after the CPU is switched from STOP to RUN, must be activated only by the Start-button. Planning Please plan your project step by step first within the team. The time to finish this project should be around 2,0 hour.


99

Programming


100


Programming

2.14

Programming – Move to Starting Position

Move your station automatically to the starting position (home position), this means, this is the position where a material flow starts. Press the Reset-button shortly to start the sequence. Station is not in starting position, the Reset-light shall flash with 500 ms, Station is in starting position, the Reset-light is on. Information Please edit the program FC1 in FBD which starts without any condition. Edit with symbols. Use the list of inputs and outputs. The OB1 is in STL. After reaching the starting position, only one output is allowed to be on, the Reset-light. Instructor: work out the starting condition together with the teams station by station. Think also about, that a workpiece could be inside the station but can not be detected by a sensor – take out by hand. Let the participants define the action themselves according the conditions. Make sure, that they follow the steps like mentioned within the planning. Planning Please plan your project step by step first within the team. Define the input conditions of the starting position first and then define the action of the actuators. The time to finish this project should be around 1,5 hour. Conditions: C1 C2 C3 C4 C5

Visual control no workpieces are on the chutes (slides) No workpiece is available (not I0.0) No workpiece inside the gripper (not I0.6) Lifting cylinder is up (I0.5) Handling at the following station (I0.2)

Actions: the actions have to be done if the corresponding condition is not fulfilled. A1 A2 A3


Remove the workpiece by hand from the chutes (slides) Remove the workpiece from the workpiece mounting by hand Move the handling to the following station

101

Programming


102


Programming


103

Programming

2.15

Programming – Expanded movement to Starting Position

Expand the Project before, that the Reset-button have to be pressed shortly in any case to make sure, the visual check is done already. Follow the steps: 1. Reset-button not pressed shortly – Reset-light flash with 500 ms 2. Reset-button was pressed shortly and Station is in home position – Reset-light is on 2. Reset-button was pressed shortly and Station is not in home position – Reset-light flash with 200 ms as long as the actuator (actuators) move to home position, after reaching the home position, the Reset-light is on. 3. Press Start-button shortly – Reset-light is off, Start-light is on The whole process (Homing and Start) can be interrupted by pressing the Stopbutton shortly or push the Emergency switch (if Emergency Stop kit is available) and the process start at the first (1.) step again. The Start process can not be activated while the homing process is active and the homing process can not be activated while the Start process is active (as long the Reset-light flash or is on the Start-button have no function, as long the Start-light is on, the Reset-button have no function). Information Please edit the program FC1 in FBD which starts without any condition. Edit with symbols. Use the list of inputs and outputs from Project 1.3 to find necessary informations. The OB1 is in STL. Instructor: Please explain very clearly what you want to have – if home-position is running it´s not able to Start, if Start-condition is running it´s not able to run the home-position sequence. Planning Please plan your project step by step first within the whole team for one station first. Use your program from Project 2.14 as a base for this program. The time to finish this project should be around 3,0 hour.

104


Programming



105

Programming

106


Programming


107

Programming

108


Programming

2.16

Project – Basics of I/O– communication

Please complete the following graphics according the description. Information Work out the basics of input/output communication together with the instructor first. Instructor: Please explain the basics of I/O-communication. Planning Please plan your project step by step first within the team. The time to finish this project should be around 1,0 hour. Execution/Documentation Please define a 1 Bit bidirectional communication network:

PLC

PLC

PNP 24 VDC Input: 0-12 VDC=0-Sig. 12-30 VDC=1-Sig. Output: 1-Sig.=24 VDC


24 VDC 0 V

Input

Output


24 VDC 0 V

Input

Output

109

Programming

Please define a 1 Bit unidirectional communication network from PLC to RobotController:

PLC

Robot-Controller


PNP 12 VDC Input: 0- 6 VDC=0-Sig. 6-12 VDC=1-Sig. max.volt.30 VDC Output: 1-Sig.=12 VDC

24 VDC 0 V

110

Input

Output

12 VDC 0 V

Input

Output


Programming

Please define a 1 Bit bidirectional communication network:

PLC

Robot-Controller


PNP 12 VDC Input: 0- 6 VDC=0-Sig. 6-12 VDC=1-Sig. max.volt.30 VDC Output: 1-Sig.=12 VDC

24 VDC 0 V

Input

k11


Output

12 VDC 0 V

Input

Output

K1

111

Programming

Please define a 1 Bit bidirectional communication network:

PLC

Robot-Controller


NPN 12 VDC Input: 0- 6 VDC=1-Sig. 6-12 VDC=0-Sig. Output: 1-Sig.=0 VDC

24 VDC 0 V

Input

k11

112

K2

Output

12 VDC 0 V

k21

Input

Output

K1


Programming

2.17

Project – Test the I/O– communication

Please test the input/output-communication with a program. Complete the drawing shown in the Execution step first. Information Please use only one program FC1 in FBD which starts without any condition to solve this problem. Edit with symbols. Use the list of inputs and outputs from project 1.3 to find necessary informations. The OB1 is in STL. Don´t use an actuator or an input twice. Fill out all c in the drawing. Actually the input/output communication is not needed for the full process, because there is a light barrier connected to each station to indicate following or previous station is in place and the material detection is on each station where it´s necessary to check the material. But the binary communication like input/output communication is very important basic knowledge to understand the next level of communication – Fieldbus Technology! Instructor: Please explain how to find the informations to finish the drawing. Explain that only one program should be used without any changes to test all inputs and outputs at the same time. Planning Please plan your project step by step first within your team and communicate with the team of the following station and the previous station if available also to complete your drawing. Finish the drawing first and then work out which button, lights or actuators you will use for this project and write it into the drawing. The time to finish this project should be around 1,5 hour.


113

Programming

Execution/Documentation

114


Programming

Program FC1, OB1 is the same than in the project before


115

Programming

116


Programming


117

Programming

Controll Edit the project and download it. Test the function according the project description and the your planning. Watch FC1 with the online-function.

118


Programming

2.18

Project – Material-flow through the FMS

One aluminium workpiece shall come from a previous station and inserted into the Handling Station, checked that the workpiece is not black and moved to the following station. After mechanical connection of the previous station and the following station, the CPU have to be set to RUN and the light barrier signal will be sent to the previous station. Before starting, the station have to be in home position (use Project 2.15). The homing position process can only be started, if the following station is in place (light barrier signal). After pressed the Start-button shortly at each station, the cycle starts. but only if the following station have been started already and is ready to take a workpiece. Information Please edit the program FC1 in FBD which starts without any condition. Edit with symbols. Use the list of inputs and outputs from Project 1.3 to find necessary informations. The OB1 is in STL. Instructor: Please explain very clearly what you want to have – if home-position is running it´s not able to Start, if Start-condition is running it´s not able to run the home-position sequence. Discuss within the whole team, how to start the cycle step by step which means, which station have to be started first, second a.s.o. Please do the planning together with the participants. Go ahead step by step and show always the condition and the action at the station directly. Explain to the participants, why a connected station is creating a 0-signal at the light barrier. Discuss the communication handshake together with all teams. Make sure, this project is not longer than 3,0 hours. Planning Please plan your project step by step first within the whole team for one station first. Use your program from Project 2.15 as a base for this project. Plan your communication with the other team carefully. Please make sure, that the communication input 1 (following station started and ready) is on as long as the workpiece is inserted into the following station. Discuss with the team of the following station also, that they have to wait for the communication output 1 (communication input 1 at the following station) to start their process. The time to finish this project should be around 3,0 hour.


119

Programming

Execution/Documentation Program FC1, the OB1 is the same than at the project before:

120


Programming


121

Programming

122


Programming


123

Programming

124


Programming


125

Programming

126


Programming


127

Programming

128


Programming


129

Programming

130


Programming


131

Programming

132


Programming


133

Programming

134


Trouble Shooting

3.1

Program – Trouble Shooting

In the following exercises there are some programming errors which have to be detected, located and eliminated. Information The programs have been part of the programming projects. Instructor: In the following you will see a list of possible errors in programs, which have been part of the programming. You will always see the Original program with no error and the screen shot of the error which have to be done within the program (please refer to the comments done by the author in the screen shots how to implement the error. Write the task always first on the board in a short form, like for example: Start-button and Reset-button = Start-light Let the participants work in the team together at the same time and take the time of each team. The time to finish the trouble shooting mentioned within the documentation means the time including preparation of the error, downloading, error detection, error location, error elimination of the participants and download an test of the correct program into the PLC. Planning Please follow the steps: error detection (what is not working) , error location (where can the error be logically), error elimination (find out the error location, change the program and test the sequence). Controll Test the program according the short description given by the instructor on the board.


135

Trouble Shooting

Original Project 2.2 (time to finish approx. 0,5 h):

136


Trouble Shooting

Error Project 2.2:


137

Trouble Shooting


138


Trouble Shooting

Error Project 2.3:


139

Trouble Shooting


140


Trouble Shooting

Error Project 2.4:


141

Trouble Shooting


142


Trouble Shooting

Error Project 2.5:


143

Trouble Shooting

Original Project 2.6 (time to finish approx. 45 min):

144


Trouble Shooting

Error Project 2.6


145

Trouble Shooting


146


Trouble Shooting

Error Project 2.7:


147

Trouble Shooting

Original Project 2.8 (time to finish approx. 45 min) :

148


Trouble Shooting

Error Project 2.8:


149

Trouble Shooting


150


Trouble Shooting

Error Project 2.9:


151

Trouble Shooting


152


Trouble Shooting

Error Project 2.10:


153

Trouble Shooting


154


Trouble Shooting

Error Project 2.11:


155

Trouble Shooting


156


Trouble Shooting

Error Project 2.12:


157

Trouble Shooting


158


Trouble Shooting

Error Project 2.13:


159

Trouble Shooting

Instructor: The following error within a program was not part of the programming projects. The Project-description is: If the Auto/Manu-switch is off a program FC1 shall be active, if the Auto/Manuswitch is on, a program FC2 shall be active. FC1 is a NOR-function with the Start-light (H1), the FC2 is a NAND-function with the Reset-light (H2). Use the Start- and Resetbutton as inputs.

160


Trouble Shooting


161

Trouble Shooting

162


Trouble Shooting

Error in Project:


163

Trouble Shooting

3.2

Process – Trouble Shooting

Please test the full process including all conditions. Find out which part of the process is not working properly and proceed with the steps: error detection, error limitation and error elimination. Please don´t forget to fill out the working-sheet of the part Execution and Documentation. The original project shall be Project 2.18. Information Besides Commissioning and Programming, the Trouble Shooting and Maintenance is one of the most important tasks in reality, because non-operating manufacturing units are causing high costs. It is much more important than in installation&commissioning or programming, to train operational steps to detect, limitate and eliminate an error as quick as possible. At Trouble Shooting there is one difference between so called “Commissioning Errors“ and “Maintenance Errors”. Both of them could be different in a way, there are NO wrong wirings, tubings as well as programming errors within the Maintenance Errors, because the system already has been running perfectly and and an operational error had happened. Such operational errors could be: • • • •

break of wire defect of elements like valves, cylinders, motors, sensors, etc. ... break of program mechanical reasons

Procedure of error elimination divides into three important fields: • error detection • error limitation • error elimination which have to be documented respectively by the trainee on the attached work sheet. An example help with the further procedure. Usually maintenance errors are easier to transform into manual training, therefore this teachware is referring only on this field regarding the solutions of its exercises.

164


Trouble Shooting

Instructor: Please work out step-by-step the difference of Commissioning- and Maintenance Errors and work out the example together with the participants. In the following you will find 14 examples of possible error locations in the table. Advice: For isolation of wire endings you can use a thin shrink tube slipped on the wire ending and heated up. This tube provides good isolation. Error

Error Location/Page No.:

Error Description

1

Isolate wire at clamp 12 directly on the PLC PLC-board/page 8 circuit no. 1

Start-button have no function à not possible to start the process after homing

2

Close the one way flow control valve of the lifting cylinder move back Pneumatic

The piston rod of the lifting cylinder cannot reach the back position after move down a workpiece à program stop

3

Isolate wire at clamp 4M directly on the PLC PLC-board/page 6

all lights are not working

4

Deadjust the sensor 2B1 for lifting cylinder in up position Pneumatic

The station is not possible to reach the homing position à no start of the sequence

5

Isolate wire at clamp 15 directly on the PLC PLC-board/page 8

Station is always in Stop-mode à can not be started

6

Isolate wire at clamp XMA2/0V from Q0 on the station Station/page 5

The handling cannot move to the previous station à handling is not possible to pick up a workpiece in the previous station

7

Isolate +-connection (red) of external power supply PLC-board/page 4 circuit no. 1

No power on the whole system

8

Remove the fuse F1 on the PLCboard PLC-board/page 4 circuit no. 1

No power supply on the PLC

9

Delete program from the PLC (simulation of battery failure)

No program execution

10

Isolate wire at clamp XMA2/3 from Q2 on the station Station/page 5

The lifting cylinder cannot move down à program stops at the position previous station

11

Isolate wire at clamp XMA2/20 from I7 on the station Station/page 4

The light barrier is always off à even there is a connected station, the Handling never receive the signal Station available

12

Deadjust the workpiece mounting

The workpiece can not be taken from the mounting à careful possible crash!!!

13

Deadjust the sensor 1B2 for handling is at following station Pneumatic

The workpiece cannot be inserted to the following station correctly

14

Isolate wire at clamp 38 directly on the PLC PLC-board/page 10 circuit no. 7

The communication output to the following station is not working à following station never start the process


Installed

165

Trouble Shooting

/6.4

9 8

/6.4

-A2DI1

O6 -XG2

7

7

-A2DI1

/6.4 /6.4

-A2DI1

6 5

/6.4

I4 -XG2 I3

16 4

3

-XMG2

-XG2

-XMG2

4

-S5

3

17

-XK1

4

/6.4

-A2DI1

/6.4 /6.4

3

-A2DI1 -A2DI1

I2 -XG2 I1

14 -XMG2

4

3 -S2

-XG2

-XMG2

4

-S3

3

15

-S4

-A2DI1

24NA

COM/5.7

-S6

-XMG2

4

3

-A2DI1

0V/8.1

24V/8.1

In the following, there is a step-by-step explanation of a sample trouble shooting. This wiring diagram is not part of the technical documentation of the Distribution Station, but show a very good example how to measure an error step by step with different measuring methods.

166

I0 -XG2

13 4

-XMG2

-S1

3

21

24VB -XG2

-XMG2

24V -XK1

2

0V/6.8

24NA/6.8 24V/6.8

Disconnection at START-Button S1


Trouble Shooting

Although the program is loaded to the PLC and normal position is reached (RESETLight flashing) the Station may not be started (RESET-Light not change to off). The starting condition is, that the Station is in normal position, which is indicated by flashing of the RESET-light. The reason for malfunction must be the START-button itself. Measuring of the current path No. 1 may be proceeded in different ways. In the following, two examples may be described, and both of them are leading to result. • measuring of voltage • measuring of continuity For better understanding, the current path No. 1 may be shown as an equivalent diagram:

disconnection XMG2 21

XMG2 13 A2DI1 2

XK1 24V 24V

R 0V 0V


PLC input

0V-clamp PLC-board

167

Trouble Shooting

Voltage test procedure 1. step:

0V

XMG2 21

XMG2 13 A2DI1 2

XK1 24V 24V

R 0V

PLCinput

0V-clamp PLC-board

0V

Voltage test procedure 2. step:

12V

XMG2 21

XMG2 13 A2DI1 2

XK1 24V 24V

R 0V 0V

PLCinput

0V-clamp PLC-board

Result: disconnection must be located between clamp XMG2 and A2DI1-2= broken wiring

168


Trouble Shooting

Continuity test 1. step:

R>

no continuity

XMG2 21

XMG2 13 A2DI1 2

XK1 24V

Attention: disconnect power supply !

R

PLCinput

0V

Continuity test 2. step:

0

continuity

disconnection XMG2 21

XMG2 13 A2DI1 2

XK1 24V

Attention: disconnect power supply !

R

PLCinput

0V

Result: disconnection must be located between clamp XMG2 and A2DI1-2= broken wiring


169

Trouble Shooting

The work-sheet for this example looks like: Order of Maintenance Name: Hellmich

Order-No: 001 310800

Location of Error: Distribution Station

Date: 31.08.2001 Sheet: 1 # 1

Error Detection After switch-on theair pressure and the PLC, the RESET-light is flashing, which means, that the system is in normal position à starting condition OK However, the station cannot be started by the Start-Button (RESET-light not change to off).

Error Limitation MECHANICAL: 1.

Is there a mechanical defect on the Start-button?

ELECTRICAL 1. Is the Start-button switching regularly? - Continuity test of switching contacts. 2. Is the signal of the button reaching the PLC? - Control by sight and voltage test.

Error Elimination REASON Break of wire (end sleeve) at the button at connection X. Attach new end sleeve to the wire and connect again. Control of total sequence = error eliminated.

Planning Please follow the description of the in instructor carefully step-by-step. Make a detailled plan of how you want to check the error location step-by-step.

170


Trouble Shooting

Execution/Documentation Follow the three steps of Trouble Shooting carefully. Write down the single steps and all useful informations into the work-sheet. Please show your result first to the instructor before removing the error!!!!! Please ask your instructor for copies of this work-sheets!!! Order of Maintenance Name:

Order-No:

Date:

Location of Error:

Sheet: Error Detection

Error Limitation MECHANICAL:

ELECTRICAL

PNEUMATICAL

Error Elimination REASON


171

Trouble Shooting

Controll After error elimination, please check the process again step-by-step carefully, there might be another error within the system.

172


Handling Instructor Rel C

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