book of implementation guidelines pfcs driver enabled self

Revision Date: 03/10/2008 of 16 Revision: 1.4

File Name: Axiom400 Reader Configuration Manual for Chrysler 10Mar08.doc

PROPRIETARY

Automatic Product Identification and Communication Systems

Book of Implementation Guidelines

PFCS Driver Enabled Self-Standing Axiom 400

Reader

AMS 0220 Section xx.x.x


Chrysler-ITN-CVM-APICS AMS 0220 Section xx.x.x



PROPRIETARY

Proprietary Notice

This document comprises legally protected subject matter proprietary to Chrysler Group LLC, and is loaned on the basis

of confidential relationship. All use and disclosure is strictly controlled. Reproduction is prohibited without the

permission of Chrysler Group LLC.

Documentation Standards, Version 2.0

Copyright 2002, Chrysler Group LLC. All Rights Reserved.





PROPRIETARY

TABLE OF CONTENTS

1.0 GENERAL...............................................................................................................................................................4

1.1 PURPOSE................................................................................................................................................................4 1.2 SCOPE....................................................................................................................................................................4 1.3 USERS....................................................................................................................................................................4

2.0 GENERAL DESCRIPTION ..................................................................................................................................4

2.1 READER TYPE........................................................................................................................................................4 2.2 SOFTWARE.............................................................................................................................................................5 2.3 ARCHITECTURE .....................................................................................................................................................5 2.4 GENERAL STEPS FOR A SUCCESSFUL INSTALLATION..............................................................................................7

3.0 CONFIGURING THE READER ..........................................................................................................................8

4.0 QUICK CONFIGURATION GUIDE .................................................................................................................13

5.0 REVISION HISTORY .........................................................................................................................................14

6.0 APPENDIX A: SUPPORTING DOCUMENTATION.....................................................................................14

7.0 APPENDIX B: GLOSSARY & CONDITIONS ................................................................................................15

7.1 TERMS & CONVENTIONS .....................................................................................................................................15 7.2 USE OF “SHALL, MAY AND SHOULD”...................................................................................................................15

8.0 APPENDIX C: CURRENT CHRYSLER NPM CODES ..................................................................................15

9.0 APPENDIX D: WIRING DIAGRAMS...............................................................................................................16





PROPRIETARY

1.0 GENERAL

1.1 PURPOSE

The purpose of this document is to provide configuration guidelines for Plant Floor Communication

System (PFCS) networks as defined by Chrysler.

1.2 SCOPE

This document provides Axiom 400 configuration guidelines that shall be followed for all PFCS

compatible self-standing applications developed for Chrysler machinery and equipment.

1.3 USERS

- Suppliers (e.g. OEMs, Integrators, Vendors)

- Chrysler (e.g. Launch Engineers, Control Engineers, Process Engineers)

- Any individual and or organization involved in the design and installation of control systems

for Chrysler.

NOTE: Chapter named “Quick Configuration Guide” is for experienced installers, skip intermediate chapters if

you have already installed such system before.

2.0 GENERAL DESCRIPTION

Note throughout this document build data/information downloads from PFCS are mentioned, the user should

have in mind that the origin of these data are either Chrysler Broadcast System or AVI WCC and PFCS WCC

only receives, logs and redirects these messages between floor equipment and WCCs.

The purpose of the PFCS (Plant Floor Communication System) communication driver is to provide a common

interface to the PFS (Performance Feedback System). Communication from the plant floor to PFCS occurs

through the PFCS Driver. This is embedded in the reader. The logic provides one communication channel to

send information to PFCS. For this driver, the channel is TCP/IP. All configuration and interfacing logic

required is documented herein. For more information on the PFCS interface, refer to the Chrysler document

titled “PFCS Vendor Specification”. (Refer to Appendix A: SUPPORTING DOCUMENTATION)

This implementation only supports the sending of “Result Data” from the AXIOM (which is the PFD or Plant

Floor Device) to the PFCS server. The AXIOM does not request or receive Vehicle data. As a result, the

AXIOM only sends message types 0006 (point of arrival message) and 9999 (two-minute apart keep alive

messages).

This reader is intended for use in areas where other means of positively identifying products in the job station

(e.g. AVI fixed readers (points), wedged hand-held readers, or tracking images) are not available or are too

costly to implement. The reader would identify the product coming into the job station and send the VIN or

Barcode to PFCS WCC. PFCS WCC in return would interrogate proper systems (Broadcast or AVI) and make

proper downloads to other PFDs or PFS terminals. This device is not recommended for more than one station

and in such cases other means of identifying products (as mentioned above) are to be used.

2.1 READER TYPE

The PFCS driver capable of handling type 2 messages is already embedded in this reader; the reader

general specifications are as follows:

1. Manufacturer Accu-Sort Systems

2. Reader Type Axiom 400 L Barcode reader

3. Firmware Image (version) axpfcs07.img

Refer to Appendix C: Current CHRYSLER NPM Codes for ordering information.





PROPRIETARY

AXIOM 400 is a laser type barcode scanner with Ethernet connection capabilities. (Figure 2-1)

Figure 2-1 AXIOM 400 barcode reader

2.2 SOFTWARE

Accu-Sort Systems AXCESS v3.0 software or higher version shall be used to configure this PFD. An

application install CD-ROM usually accompanies the reader shipment package. The image files are a

sample configuration is available on APICS website.

2.3 ARCHITECTURE

Figure 2-2 depicts current available laser barcode reader types and their integration in Chrysler IT

infrastructure. (Note the RF ID readers are not shown here).

NEW

PA ENET

PFCS WCC

AVI WCC

Mistake Proofing Box

WinCE SBC+uLgx1200

DCX WAN/Broadcast

PLC

ENET

AVI Comm

Optical BarcodeFixed Reader

PFS Terminal

EnterpriseLevel

AVI Supervisor

(PLC 5)

DCM

AVI Comm

Direct Wire or W/less

Prop.

3/14/2006APICS Available

Readers

DCX-ITN-CVM-APICS

RDC

HMI Unit (Typical)

Supervisory/WCCLevel

Advanced Control

Level

Control

Level

DeviceLevel

PFS Terminal

RS-422Prop.

Plant Floor

Level

Line/ShopLevel

Cell Level

Plant

Level

AVI point

STP

RIO

ENETPFCS

TCP/IP Enabled

Tool

TCP/IP or AB Client

PFCS

ENETPFCS

Hand HeldReader

Hand HeldReader

ENET TCP/IPPFCS

TCP/IP Enabled

AXIOM Reader

1 2

5

5

3

4

4

3

Figure 2-2 General APICS readers architecture





PROPRIETARY

A typical (successful) transaction scenario is marked by numbered triangles in Figure 2-2 and is

completed as follows:

1. A vehicle (product) enters (or approaches) the job station triggering the sensing mechanism. This

in turn turns on the laser beam (Beam ON Trigger). The barcode is read and a PFCS message type

0006 is sent to the PFCS WCC.

2. PFCS WCC responds to the device by acknowledging the receipt of data (sending an “ACK”).

3. PFCS WCC in turn interrogates Broadcast (BCS) or AVI systems.

4. BCS or AVI send downloads to designated station (adjacent to the reader) via PFCS WCC.

5. PFCS WCC relays this message to proper tool or PFD.

From this point on a new set of transactions are started; for details refer to “PFCS Vendor

Specification” document in Appendix A: SUPPORTING DOCUMENTATION.

The reader laser beam can be turned on/off using an external triggering mechanism as shown in Figure

2-3 this could be a photo-eye (PE), a limit-switch (LS), push-button (PB) or software triggered.

Figure 2-3 Typical Single-Unit Axiom Application (From AXIOM™ 400 Product Manual pp. 5-7)

A simplified schematic diagram of the required connection for items in Figure 2-2 and Figure 2-3 is shown

below:

Figure 2-4 Schematic Diagram of Typical Single-Unit Axiom Installation (Source: Ditto Figure 2-3 )

Note: PC and programming cable are not part of the normal installation and are used only to configure the unit.





PROPRIETARY

2.4 GENERAL STEPS FOR A SUCCESSFUL INSTALLATION

The following is a list of tasks to be performed for a successful installation. Of course details of each

project may constitute addition or deletion of tasks and routines to what is stated here.

2.4.1 Pre-installation

• Site survey: Survey the station that installation is recommended make sure general reader

installation recommendations mentioned in “AMS 0220 Section 14.1.1” (Ref. Appendix A)

hold.

• Connection needs: Each unit needs two regular 110-120 VAC power outlets (for the unit and

the stack lights) and a PA (Plant Automation) Ethernet network drop.

• Location considerations:

1. Reader: When reader beam is on; operators shall not be exposed to laser rays.

2. Triggering mechanism: Photo-eyes or limit switches (PE or LS) signals shall be solid

and turn the beam on in time for proper reading of the device, also the duration of

trigger is very important so that labels are scanned in their entirety.

3. Network latencies: Have in mind that five transactions are to be performed on a high

traffic network, therefore positioning of the reader and trigger with respect to the

operator’s job station shall be considered so that it ensures in time delivery of the

information when the product is present in the station. This is necessary for positive

attribution of quality data to the right product.

2.4.2 Installation

• AC Power feeds for reader and the stack light unit.

• PA Network drop

• Powering up and hardware troubleshooting according to AXIOM user manual (Ref. Appendix

A).

• Fill out the form in Quick Configuration Guide chapter.

2.4.3 Configuration

• For configuring the reader refer to Chapter 3 of this document.

• PFCS WCC configuration: Coordinate this with project PFCS Rep. (Ref. to Appendix B)

2.4.4 Commissioning and Certification

• Certify the installation according APICS published document. (Ref. Appendix A).





PROPRIETARY

3.0 CONFIGURING THE READER

Before configuring the reader, verify proper reader installation requirements according to documents in

Appendix A. Also make sure the latest firmware image is installed.

Use AXCESS software for configuring this PFD.

1. First connect to the reader (using the serial programming cable or network connections).

Note: if this is the first time you are connecting to the reader, use the special serial programming cable (available

in Appendix C: Current CHRYSLER NPM Codes ) to connect to the reader. AXCESS application automatically

detects default settings for connecting to this device.

Figure 3-1 Connecting AXIOM 400 to PC via serial cable





PROPRIETARY

2. On “Axiom Configuration” screen change the reader name to “Machine ID” designated by PFCS Rep (Refer to

Appendix B: GLOSSARY & CONDITIONS), as shown in Figure 3-2. In other words The Machine ID for the

AXIOM can be specified by setting the “Reader Name” on the AXIOM Configuration window. Also make sure

the software name/revision is the latest and greatest specified by APICS (available on APICS website).

Figure 3-2 Axiom General Configuration Screen

3. On “Bar Code Setup” and “Bar Code Groups” screens set up for proper barcode or VIN labels as directed by

project manager.





PROPRIETARY

4. On Bar Code “Padding and Stripping” screen change the following as shown in Figure 3-3.

1) Select “Strip Selected Characters” and for cut the unnecessary characters off of the VIN (usually you

do not need to strip characters off of a barcode.

2) Choose “Add Padding”.

3) Assemble PFCS Message type 0006 by adding the conveyor ID and target station’s ID before the

Barcode/VIN add (per PFCS vendor specification document).

4) Complete step 3 by adding the type of label read (“B” for Barcode and “V” for VIN) and three blanks.

Example 1: for barcode "3AXP11234AXB1+BC+Bbbb"

Where:

3 = Send the message to PFS & PFCS

AXP1= four (4) alphanumeric conveyor ID

1234 = foot position of the station that point of arrival is sent to (Not applicable here)

AXB1=Station ID

BC = Barcode that is read (8 characters) and is automatically inserted by the reader

B=Indicator that the ID read is a Barcode

bbb=Three blanks that are inserted after character "B"

Example 2: for VINs "3CONV1234STN1+BC+Vbbb"

Where:

3 = Send the message to PFS & PFCS

CONV= four (4) alphanumeric conveyor ID

1234 = foot position of the station that point of arrival is sent to (Not applicable here)

STN1=Station ID

BC = VIN that is read and stripped (8 characters) and is automatically inserted by the reader

V=Indicator that the ID read is a VIN

bbb=Three blanks that are inserted after character "B"





PROPRIETARY

Figure 3-3 Barcode Padding and Stripping Screen

5. Set up the IP address, subnet mask and gateway IP address for the reader (Area marked as “1” in Figure 3-4).

6. To enable PFCS communications, the following settings must be applied to a Network Host Port. (Area marked

as “2” in Figure 3-4).

• Set Connection Type to “TCP/IP Client.”

• Specify a message format of “Custom Message.”

• Set up the PFCS WCC (server) IP address in the field labeled “Remote IP Addr.” (obtain the

information from PFCS Rep.)

• Set up “Port #” in the field labeled “Port #.” (obtain the information from PFCS Rep.)

• The Timeout value (in seconds) is specified as the “Reconnect Time” change this to 5. The number of

retries is always three (3).





PROPRIETARY

Figure 3-4 Network Setting Screen

7. Setup the trigger and Relay settings per project requirements.

8. Save these configuration values to the reader, the base of the device and on a file and deliver the file to your

PFCS Rep.

This concludes the set up, make sure the device is properly connected to the plant automation Ethernet network

(PA) and the PFCS WCC is configured to accept the messages.





PROPRIETARY

4.0 QUICK CONFIGURATION GUIDE

Note: This part is for experienced installers, others are required to read and understand the whole document in

addition to the supporting documents.

Fill out the following table and configure the device.

ITEMITEMITEMITEM ValueValueValueValue ��

Obtain these from Project PFCS Rep.

Machine ID for this reader; insert as the device name.

(A four character alphanumeric value; e.g. RDR4)

Reader designated IP Address; insert for “IP Address” field.

(PA IP address four octets; e.g. 53.230.117.249)

Subnet mask; (e.g. 255.255.254.0)

Gateway IP address; (e.g. 53.230.116.1)

Port # for this reader

(A numeric value between 1024-65,535; e.g. 3101)

PFCS WCC IP Address; insert for “Remote IP Addr.” field.

Padding/Stripping string (Ref

After configuring the device observe the following statuses for of each status LED.

1. Status LED should be GREEN

2. Trigger LED should be GREEN whenever the trigger is on

5. Network LED should be OFF

6. Link LED should be flashing green





PROPRIETARY

5.0 REVISION HISTORY

Date Revision Number* NAME Description (include pages affected)

3/10/08 1.4 H. Gehringer Updated Chrysler References

01/04/07 1.3 N. Bayan Added examples for padding and striping.

07/21/06 1.2 N. Bayan Corrected text for MSG Type 006.

07/20/06 1.1 N. Bayan Corrected for approved code and screen shots for MSG Type 006.

03/09/06 1.0 N. Bayan Initial Release.

6.0 APPENDIX A: SUPPORTING DOCUMENTATION

The user should have a good understanding of the following documents and shall ensure that the latest revision of each

document is used.

Doc. No. Title

AMS 0220 Section 11.1.1 Chrysler PFCS Vendor Specification (BOIG),

Available on AME website.

AMS 0220 Section 14.1.1 AVI/VMS Barcode Reader Placement Guidelines

AXIOM™ 400 Bar Code Scanning

Solutions, Product Manual

Accu-Sort Systems, PN 1000055015 1.0, CMS 04-0372-01,

02.22.05.*

AXCESS™ V3.0, for the AXIOM™

Line of Bar Code Readers, Software

Manual

Accu-Sort Systems, PN 1000057289 3.0, CMS 04-0270-01,

02.14.05.*

AXIOM™ 400 Reader Certification

Document

Certification document*

*Available on APICS website:

Intranet: http://apics.intra.chrysler.com/wi/clients/apics_e;

(select “Systems”, “Plant Floor Downloads” and then “Readers”)

Extranet (via Covisint): http://chrysler.covisint.com





PROPRIETARY

7.0 APPENDIX B: GLOSSARY & CONDITIONS

7.1 TERMS & CONVENTIONS

Glossary

BOIG Book of Implementation Guidelines

CLx ControlLogix

ID Identification

JSR Jump-to-Subroutine

ms Millisecond

N/A Not Applicable

SUPPLIER Original Equipment Manufacturer

PFCS Plant Floor Communication System

PFS Performance Feedback System

PLC Programmable Logic Controller

WCC Work Cell Controller

PFD Plant Floor Device

ENET Ethernet

PFCS Rep. Refers to plant ITN personnel, ASLM or APICS representative that could

supplier the installer (Supplier, OEM) with configuration information such as

machine ID, Port # and PFCS WCC IP address.

PA Plant Automation Network (Ethernet)

7.2 USE OF “SHALL, MAY AND SHOULD”

The word “shall” is understood as a requirement. The word “should” is understood as a

recommendation or preference. The word “may” is understood to specify a specification that is

condition dependent. The designer or vendor may be required to justify a deviation from the standard,

and may be required by an authorized Chrysler representative to make alterations so as to conform.

8.0 APPENDIX C: CURRENT CHRYSLER NPM CODES

Table below lists Accu-Sort Systems Inc’s products that are used for a successful installation. Verify these with APICS

Approved Source List (ASL).

Item Description OEM P/N Chrysler NPM code QTY/1*

AXIOM 4L SCANNER. P/N 1000052800 60-040-0001 1

ACCUSORT WIRING BASE US VERSION. P/N 0104636001 60-040-0002 1

ACCUSORT OUTPUT MODULE 3-60VDC. P/N 1000056136 60-040-0003 2

ACCUSORT INPUT MODULE 3-60VDC. 2

AXIOM 110V POWER SUPPLY. P/N 0105365001 60-040-0004 1

AXIOM SCANNER MOUNTING BRACKET W/POWER

SUPPLY ADAPTER.

P/N 0105307002 60-040-0005 1

AXIOM READER STATUS INDICATOR INCLUDES RED &

GREEN INDICATOR LAMPS, BASE ENCLOSURE, &

INTERFACE CABLE.

P/N 1000022661 60-040-0006 1

PROGRAMMING CABLE. P/N 1000007308 60-040-0007 1

* Means quantity per one complete installation (one unit and accessories).





PROPRIETARY

9.0 APPENDIX D: WIRING DIAGRAMS

Figure 9-1 Stack-light box connector wiring diagram (Based on Accu-Sort DWG # E3124259)

TCP/IP Enabled AXIOM Reader110-120 VACPower Outlet

RJ-45 Ethernet

Wall Plug

Trigger Sensor

CAT 5 Ethernet cable

Stack Light

Interconnection Diagram

4 #22 AWG+2SP (detail in Fig. 9-1)

2 #12 AWG+1 GND/120VAC cable

2 or 4 #22 AWG+1 GND

Figure 9-2 Interconnection diagram

book of implementation guidelines pfcs driver enabled self

Documents