Order-NR.:
Type: Manual prolog-factory Designation Prolog_Manual_A005.doc Printed: August 13
Autor: Schober Graphics: Schober
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.
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
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
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
4.3.3 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
5.8.1 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
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
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
combined 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 produced
The 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
Overview prolog-factory system 2.2 Customer system
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.
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 are passed on via the electrical sorting gate.
2.2.4 Pick and place station
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.
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.
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 material flow 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.
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.
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
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 the commissioning 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.
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 steps can 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.
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)
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 components
Adjusting sensors and limit switches in automated systems Commissioning systems by means of a PLC
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
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 such damage 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 2.6 Warranty and
liability
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.
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! 3.1 Handling the system
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 safety devices.
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.
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
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
suitable 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.
4.2.1 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.
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, this must 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.
4.3.3 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)
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.
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
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
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
system, 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. 5.1 General 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.
5.2.1 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
Position numbers Robotino / orientation of pallets
Position Position number robotino
1 High bay rack position 1 2 High bay rack position 2 3 High bay rack position 3 4 High bay rack position 4 5 High bay rack position 5 6 High bay rack position 6
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
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.
The memory card with the system software has to be available in the slot of the robotino.
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
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.
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. 5.4 Program start
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 robotino
In RobotinoView 2 select the tab Main program
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:
Close the UPD connection control window and click on Upload project in the menu robotino
The FTP client within RobotinoView opens and connects to Robotino. The IP address of the Robotino is entered in both IP address fields.
If successfully connected, the Robotino directories are displayed. Open the programs directory with a double click.
Click on Upload current project to upload the opened program
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.
5.5.1 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 this
position:
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. The Robotino leaves the dock.
8. Save the right parameters: save the target-position for the Robotino and the fork.
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:
The Robotino leaves the dock.
Save the right parameters: save the target-position for the Robotino. In the same time, the Robotino drives to the target-position and initialize the
fork.
The Robotino finds the metallic line (with inductive sensor and odometry). The Robotino finds the black band (with optical sensor).
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.
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
5.7.1 General
Position Function Positi
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
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)
High bay rack
Position Function
1 High bay rack position 1 2 High bay rack position 2 3 High bay rack position 3 4 High bay rack position 4 5 High bay rack position 5 6 High bay rack position 6
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
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
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
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 the following 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
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
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
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! 6.1 System information
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 6.2 Use Runtime
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 6 Choose 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
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 window warning
Position Function
1 Detailed alarm announcement / background grey for warning 2 Acknowledge and delete all alarms
Alarm window / error
Position Function
1 Detailed alarm announcement / background red for error 2 Acknowledge and delete all alarms
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
Configuration window
Position Function
1 Fault is announced (only in flash animation) / marked with the red frame 2 Description of fault
management. 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 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 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.
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 7 Button to disable all orders 7.3 Operation
Pos. Description Pos. Description 11 Announcement of actual order in new window
(See screen commissioning order)
16 Announcement of actual order in new window, it is possible to delete orders in the window 12 Announcement of actual order in new window
(See screen commissioning order)
17 Announcement of status guilty for all stations green = online / red =offline
13 Announcement of actual order in new window (See screen commissioning order)
18 New window with right click/See screen inventory
14 Announcement of actual order in new window (See screen commissioning order)
19 Announcement of actual order in new window (See screen commissioning order)
15 If a pallet is available at a penholder position, the position is marked green
Pos. Description Pos. Description
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
Analysing orders
Announcement of all produced orders. In the top area some choices can be done.
Analysing parts
Configuration – resources
Pos. Description
1 Change mode (see following screens) 2 Choose configuration area
Configuration – production orders
Pos. Description
1 Change mode (see following screens) 2 Choose configuration area
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
Configuration – buffers
Pos. Description
1 Change mode (see following screens) 2 Choose configuration area
3 Announcement of storage / each line is one shelf, the content is announced or editable, / the blue line is the active shelf
Configuration – customer data
Pos. Description
1 Change mode (see following screens) 2 Choose configuration area 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
Configuration – generated orders
Pos. Description
1 Change mode (see following screens) 2 Choose configuration area
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
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
Show commissioning order
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
7. On a commissioning order a delay time and a output slide can chosen 8. 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
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
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 magazine Empty: 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 empty Else
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 Sequence of distribution
