ciros mechatronics manual 1

572757 EN

01/2010

CIROS®

Mechatronics

Manual

2

Order No.: 572757

Edition: 01/2010

Authors: Christine Löffler

Graphics: Doris Schwarzenberger

Layout: 07/2010, Beatrice Huber, Julia Saßenscheidt

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, 2004-2010

Internet: www.festo-didactic.com

E-Mail: [email protected]

The copying, distribution and utilization of this document as well as the

communication of its contents to others without express authorization

is prohibited. Offenders will be held liable for the payment of damages.

All rights reserved, in particular the right to carry out patent, utility

model or ornamental design registration.

© Festo Didactic GmbH & Co. KG „ 572757 3 3

1. What will you learn from the manual? ____________________ 7

2. This is how you install CIROS® Mechatronics _____________ 10

3. These functions support you with the preparation

of PC workstations for students _______________________ 11

3.1 Description of files for a process model _________________ 11

3.2 Creating a user-specific work environment _______________ 12

3.3 Creating files with fault settings for a process model ______ 14

4. The CIROS® Mechatronics system ______________________ 16

4.1 Overview of CIROS® Mechatronics _____________________ 16

4.2 The process models of CIROS® Mechatronics _____________ 18

4.3 Controlling the process models via internal PLC __________ 26

4.4 Controlling the process models via external PLC __________ 27

4.5 Functions for fault setting in the process model___________ 29

4.6 Functions for the analysis of process models _____________ 30

5. Important control functions of CIROS® Mechatronics ______ 32

5.1 Loading a process model _____________________________ 32

5.2 Simulating a process model___________________________ 41

5.3 Displaying and operating a process model _______________ 45

5.4 Changing the view of a process model __________________ 51

5.5 The Inputs and Outputs windows ______________________ 55

5.6 The Manual Operation window ________________________ 56

5.7 Controlling a process model via the internal S7 PLC _______ 70

5.8 Controlling a process model via the external

Soft PLC S7-PLCSIM _________________________________ 80

5.9 Controlling a process model via the external

Soft PLC CoDeSys SP PLCWinNT _______________________ 92

5.10 Controlling a process model via an external PLC _________ 116

5.11 Setting faults in a process model _____________________ 132

5.12 Eliminating faults in a process model __________________ 139

5.13 Logging of eliminated faults _________________________ 144

Contents

Contents

4 © Festo Didactic GmbH & Co. KG „ 572757 4

6. The following training contents can be taught with

CIROS® Mechatronics _______________________________ 146

6.1 Training contents __________________________________ 146

6.2 Target group ______________________________________ 147

6.3 Previous knowledge ________________________________ 148

6.4 Example: Assigning training aims to training courses _____ 148

6.5 The training concept of CIROS® Mechatronics ___________ 153

7. This is how you establish the mode of operation and

structure of a system in CIROS® Mechatronics ___________ 155

7.1 Training aims _____________________________________ 155

7.2 Methods _________________________________________ 156

7.3 Support via CIROS® Mechatronics _____________________ 160

7.4 Example _________________________________________ 160

7.5 Example _________________________________________ 166

7.6 Example _________________________________________ 171

8. This is how you establish the mode of operation of

the components forming part of a system in

CIROS® Mechatronics _______________________________ 176

8.1 Training aims _____________________________________ 176

8.2 Methods _________________________________________ 177


8.4 Example _________________________________________ 178

9. This is how you use CIROS® Mechatronics in

PLC programming __________________________________ 185

9.1 Training aims _____________________________________ 185

9.2 Methods _________________________________________ 186


9.4 Example _________________________________________ 188

9.5 Example _________________________________________ 197

Contents


10. This is how you carry out systematic fault finding on

a simulated system ________________________________ 208

10.1 Training aims _____________________________________ 208

10.2 Methods _________________________________________ 209

10.3 This is how CIROS® Mechatronics supports you __________ 216

10.4 Example _________________________________________ 216


CIROS® Mechatronics is an application from the CIROS® Automation

Suite.

CIROS® Mechatronics is a PC-based graphic 3D simulation system

consisting of preassembled process models. These process models

represent automated systems of varying complexity.

CIROS® Mechatronics is a tool, which enables you

to familiarise yourself with the mode of operation and structure of a

system,

to practise PLC programming and testing of the PLC programs und

to carry out systematic fault finding on systems.

These process models, also called work cells, are also available in the

form of actual systems.

In addition to the ready-made process models, CIROS® Mechatronics

also offers you the option of simulating process models of your own

design. You can create and modify process models using CIROS®

Studio, which is a further application available from the CIROS®

Automation Suite.

This manual is intended for

Trainers and teachers

The manual provides ideas and suggestions on how CIROS®

Mechatronics can be used for tuition in vocational and further

training.

Trainees and students

The information and instructions on how to operate COSMIR®

MECHATRONICS are of particular interest to the above.

The manual is subdivided into the following subject areas:

Chapter 2 contains information and notes regarding the installation

and licencing of CIROS® Mechatronics.

Chapter 3 contains information on how to set up CIROS®

Mechatronics on students’ PC workstations.

1. What will you learn from the manual?

What is CIROS®

Mechatronics?

Target group

Composition of the manual



Chapters 4 and 5 describe the system and the main user functions of

CIROS® Mechatronics.

Chapter 6 deals with didactic aspects and lists the training contents

taught with CIROS® Mechatronics . It also describes the training

concept and the resulting possibilities for use in tuition.

Chapters 7 to 10 describe actual problem definitions regarding the

training contents, the methodical approach to solutions and their

realisation in CIROS® Mechatronics. The exercises are for example

carried out on the Distributing station.

Certain print formats have been used for text as well as key

combinations and sequences to enable you to find information more

easily.

Print format Meaning

Bold This format is used for command names,

menu names, dialog window names, directory

names and command options.

Key1 + key2 A plus sign (+) between the key names means

that you must press the keys mentioned

simultaneously.

Key1 ‟ key2 A minus sign (‟) between the key names

means that you need to press the keys

mentioned in succession.

Additional descriptions and support are available via the on-line Help.

The on-line Help comprises

CIROS® Help with operation and

CIROS® Mechatronics Assistant.

Conventions

Additional support



The on-line Help consists of detailed information regarding the

functions and operation of CIROS® Mechatronics .

CIROS® Help is a component part of the CIROS® Automation Suite and

describes the functionality of various, different CIROS® applications.

The functional scope of CIROS® Help is therefore greater than that

required for CIROS® Mechatronics.

The menu bar of the on-line Help provides functions that you are

already familiar with from using a standard Internet browser. These

include: Next and back, select start page, print selected topics, show

and hide the navigation bar or Internet connection options.

The additional indexes such as Contents, Index, Search or Favourites,

furthermore give you the option of conveniently navigating through the

information provided in the Help menu of CIROS® Mechatronics .

CIROS® Mechatronics Assistant provides detailed function descriptions

and technical documentation for the individual process models. It also

comprises a sample PLC program for the more complex process models.

The PLC program is created in STEP 7.

Moverover, CIROS® Mechatronics Assistant offers you direct access to a

particular process model.

Adobe Acrobat Reader will need to be installed on your PC to view PDF

documents. The Adobe Acrobat Reader program is available free of

charge and can be downloaded via the Internet address

www.adobe.com.

Our telephone Hotline is available 24 hours, should you have any

queries when installing or commissioning CIROS® Mechatronics .


To install CIROS® Mechatronics you will need the CIROS® Automation

Suite DVD-ROM, where all the software packages of the CIROS®

Automation Suite are ready for installation. It also includes the manuals

in the form of PDF documents for the individual software packages.

On completion of the installation, you will need to execute the licencing.

As soon as this is successfully completed you can start CIROS®

Mechatronics.

For further information regarding system requirements, installation and

licencing, please refer to the enclosed instructions.

2. This is how you install CIROS® Mechatronics


CIROS® Mechatronics consists of functions to support you in the use of

the software program during training.

These include:

An individual working environment that can be set up on each

student’s PC. This working environment stores user specific data for

CIROS® Mechatronics.

Files with fault settings for a process model can be centrally set up

by instructors and easily copied to the PC workstation of the

students.

The example of the Distributing station process model is used to

demonstrate which files belong to a process model and what

information is stored in these files.

The name of the directory for the Distributing process model is

DistributingStation.

File Description

DistributingStation.mod Process model for simulation. The process model is controlled via the

internal S7 PLC as standard.

DistributingStation.ini Initialisations for the process model: This file contains all user specific

settings for the process model such as window configuration, fault

settings, etc.

DistributingStation.prot Protocol of fault localisation: This file is read in the teacher mode and

displayed in the fault log window.

DistributingStation.htm

DistributingStation.xls

DistributingStation.txt

Export of fault log: Changes in the fault log are automatically exported to

these files. These files can then for instance be viewed via Microsoft

Internet Explorer or Microsoft Excel.

DistributingStation.mcf Settings regarding fault setting: This file contains all settings regarding

the activation, start, duration and type of a fault. If this file exists in the

process model directory, then it overwrites the settings in the INI file. If

not, then the fault settings stored in the INI file are used.

3. These functions support you with the preparation of PC workstations for students

3.1

Description of files for a

process model



User-specific working environments consist in the main of the process

models and files with the user specific data.

User specific data are:

Window configurations,

Settings for the process model,

Settings regarding fault setting,

Protocol of fault localisation.

In order to create a user-specific working environment, the process

models are saved to a separate directory on the PC. Any user specific

data is then also stored in this directory.

For example, to set up the working environment for three different users

on one PC, you will need to copy the process models into three different

directories. Each user will then be working with “his/her own” directory,

which corresponds to the user’s working environment. The user loads

the process models with which he/she is working in CIROS®

Mechatronics from „his/her“ directory.

CIROS® Mechatronics supports you with the setting up of user specific

working environments. To do so, open up CIROS® Mechatronics

Assistant.

CIROS® Mechatronics differentiates between reference models und

user models.

Reference models are filed in the program directory of CIROS®

Mechatronics and are write protected. The model and associated

PLC program cannot be modified. This ensures that the process

model can be opened and correctly simulated at any time.

User models, if created and opened with the help of CIROS®

Mechatronics Assistant, are filed as standard in your personal folder

under My Documents\CIROS\CIROS Mechatronics Samples. These

are not write protected and you therefore can for example modify

the appropriate PLC programs and replace these with your own. The

program directory with the user models represents your individual

working environment for CIROS® Mechatronics.

3.2

Creating a user-specific

work environment



You can also copy the user models into a folder other than into the

standard preset folder. You will find the information for this in CIROS®

Mechatronics Assistant.



Files with fault settings for a process model can be created centrally by

teaching staff and copied to the PC workstations of students in a simple

manner.

This is how you create a file centrally with fault settings for a process

model:

1. Start CIROS® Mechatronics .

2. Load the desired process model, e.g. the process model Distributing

Station. The process model is to be controlled via the internal PLC.

3. Open the Fault Setting window. To do so, activate Fault Setting

under Fault Simulation in the Extras menu.

4. The Fault Setting window opens once you have entered the

password.

5. Now set a fault ‟ for example for the PLC input 1B1.

6. Activate the context sensitive menu via the right mouse button and

select the option Export.

3.3

Creating files with fault

settings for a process

model



7. The faults set for the process model DistributingStation.mod have

been exported to the file DistributingStation.mcf. You will find this

file in the same directory, in which the process model loaded at the

time is also stored.

8. Now copy the file with the fault settings to the user specific working

environments. Select the directory in which the relevant process

model is stored as directory, in this case the Distributing Station

process model.


CIROS® Mechatronics comprises the following:

The simulation software CIROS® Mechatronics

The communication software EzOPC

The on-line CIROS® Mechatronics Help

The on-line CIROS® Mechatronics Assistant

Online Help for EzOPC

A PDF document with information regarding the licencing and

installation of a licence server

A manual in the form of a PDF document for the operation of CIROS®

Mechatronics

CIROS® Mechatronics is a PC-based 3D simulation system with

preassembled process models.

In addition, CIROS® Mechatronics also offers you the option of

simulating process models of your own design apart from the

preassembled process models. You can create and modify process

models using CIROS® Studio, which is a further product from the

CIROS® Automation Suite.

Internal S7 PLC

EasyPort

ExternalPLC

S7-PLCSIM

Operatingfunctions

CIROS®

assistant

CIROS®

helpProcess models

MC7-Code

OPC-Client

EzOPC (OPC-Server)

CoDeSys PLCWinNT

Component parts of CIROS® Mechatronics

4. The CIROS® Mechatronics system

4.1

Overview of

CIROS® Mechatronics



The following are required to simulate the operation of a process:

A PLC and PLC program to control the process,

The simulation to simulate the behaviour of the process. This

simulation ensures for example, that cylinders move and sensors

are activated.

Sample PLC programs are available for complex process models. These

PLC programs define a possible process control system. You can of

course create new PLC programs that generate a different process

execution.

When loading a process model, the sample PLC program is

automatically downloaded at the same time, provided that it exists. The

PLC program is executed via a SIMATIC S7 simulator. This S7 simulator

is a component part of CIROS® Mechatronics . The integrated

S7 simulator is also referred to as the internal PLC.

Once the process model has been loaded, the process can be simulated

immediately.

The advantage with this is that you can familiarise yourself with,

activate and monitor the process. Plus there is no need for you to have

created a PLC program beforehand.

One particular additional function offered by CIROS® Mechatronics is

the possibility of simulating faults, whereby you can set typical faults in

a process model. The following can for example be causes of

malfunction: A mechanically displaced sensor, a cable break or failure

of an entire module. The cause of the fault must be found by means of

systematic fault finding and eliminated.

One of the main focal points of CIROS® Mechatronics is the monitoring

and analysis of processes and elimination of faults.

Another focal point is the creation of your own PLC programs for the

process models. These PLC programs are loaded to an external PLC and

CIROS® Mechatronics exchanges the input/output signals with the

external PLC via the OPC interface.



The following can be used as external PLCs

Any actual PLC

The Soft PLC SIMATIC S7-PLCSIM

The soft PLC CoDeSys SP PLCWinNT

CIROS® Mechatronics requires the software program EzOPC for

connection to an external PLC. The OPC server EzOPC communicates

with any PLC via the EasyPort interface.

The process models are realistic replicas of actual working stations and

modules.

For each process model, there is a work cell.

An exception is the MPS B distributing, processing and sorting stations.

For these process models, there are three work cells in each case. It is

apparent from the name, via which PLC the process model is to be

controlled. For example, in the case of the MPS distributing station this

is as follows:

DistributingStation_B.mod:

Control via the internal S7-PLC.

DistributingStation_B(PLCSIM).mod:

Control via the external PLC S7 PLCSim.

DistributingStation_B(EasyPort).mod:

Control via an external PLC via EasyPort.

In the case of the MPS B testing station, there is only one work cell due

to the analogue processing. This work cell is controlled via the internal

S7-PLC.

For all other process models, precisely one work cell is available. The

setting as to which PLC is to control the process model can be effected

in a CIROS® Mechatronics menu item.

4.2

The process models

of CIROS® Mechatronics



Process model Description File name

Processing Station

The process model represents a

simulation of the MPS Processing

Station of Festo Didactic. In this

work cell, workpieces are to be

tested, processed and transferred

to the adjacent station. A sample

PLC program is available for this

process model.

ProcessingStation.mod

B Processing Station


simulation of the Festo Didactic

MPS B Processing Station. In this


tested, processed and transferred

to the adjacent station. A sample


process model.

ProcessingStation_B.mod

ProcessingStation_B(PLCSIM).

mod

ProcessingStation_B(EasyPort

).mod

Fluidic Muscle Press Station


simulation of the MPS Fluidic

Muscle Press Station of Festo

Didactic. In this work cell,

workpiece inserts are to be press-

fitted with workpiece housings

and the finished workpiece

transported to the transfer

station. A sample PLC program is

available for this process model.

FluidicMuscleStation.mod




Handling Station



MPS Handling Station. In this


removed from a retainer and,

depending on the results of

material testing, deposited on a

slide. A sample PLC program is


HandlingStation.mod

Stacker Store Station



Stacker Store. In this work cell,

workpieces are to be put into and

removed from storage. A sample


process model.

StoreWorkCell.mod

Pick & Place Station



MPS Pick & Place Station. In this

work cell, workpiece inserts are to

be placed onto the workpiece

housings and the complete

workpiece transported to the

transfer position. A sample PLC

program is available for this

process model.

PickAndPlaceStation.mod




Testing Station



MPS Testing Station. In this work

cell, the material characteristics

of the workpieces is to be

determined and the workpiece

height checked. Depending on

the test result, the workpiece is

either ejected or transferred to

the adjacent station. A sample


process model.

TestingStation.mod

B Testing Station



MPS B Testing Station. In this

work cell, the material quality of

the workpieces is to be

determined and the workpiece

height checked. Depending on

the test result, the workpiece is to

be ejected or transferred to the

adjacent station. A sample PLC


process model.

TestingStation_B.mod

Note:

The process model can only

be controlled using the

internal PLC.

Buffer Station



MPS Buffer Station. In this work

cell, workpieces are to be

transported, buffered and

separated out. A sample PLC


process model.

BufferStation.mod




Sorting Station



MPS Sorting Station. In this work

cell, workpieces are to be sorted

according to material and colour.

A sample PLC program is


SortingStation.mod

B Sorting Station



MPS B Sorting Station. In this


sorted according to material and

colour. A sample PLC program is


SortingStation_B.mod

SortingStation_B(PLCSIM).mo

d

SortingStation_B(EasyPort).m

od

Separating Station



Separating Station. In this work

cell, workpieces are to be

differentiated and separated into

two material flow directions. The

basic bodies for the cylinder are

further transported on conveyor

1, and the housings for the

measuring instruments on

conveyor 2, and then transferred

to the adjacent stations. A sample


process model.

SeparatingStation.mod




Distributing Station



MPS Distributing Station. In this


separated out and transferred to



process model.

DistributingStation.mod

B Distributing Station



MPS B Distributing Station. In this


separated out and transferred to



process model.

DistributingStation_B.mod

DistributingStation_B(PLCSIM

).mod

DistributingStation_B(EasyPor

t).mod

Rotary Indexing Table Module



MPS Rotary Indexing Table

module. In this work cell,

workpieces are to be tested and

polished in two parallel

sequences.

RotaryTable.mod




Stacking Magazine Module



MPS Stacking Magazine module.

In this work cell, workpieces are

to be separated out from the

magazine.

StackMagazine.mod

Changer Module



MPS Changer module. In this


picked up by a vacuum suction

cup and transferred by means of a

semi-rotary actuator.

ChangerModule.mod

Sorting System Project Module


simulation of the Sorting System

project module of Festo Didactic.

In this work cell, workpieces are

to be transported via the

conveyor belt and sorted

according to different material

characteristics.

A sample PLC program is


SortingSystem.mod




Conveyor Project Module


simulation of the MPS Conveyor

project module of Festo Didactic.

The conveyor enables you to

connect MPS stations. The

conveyor is to transport and

buffer workpieces. The conveyor

is available in four stages of

expansion. A sample PLC program

is available for this process

model.

Conveyor1.mod

Conveyor2.mod

Conveyor3.mod

Conveyor4.mod



The PLC integrated into CIROS® Mechatronics is a SIMATIC S7 simulator.

The S7 simulator can execute LDR, FCH and STL programs created in

STEP 7.

The internal PLC executes the sample PLC programs provided for the

process models and enables you to immediately simulate the

processes.

Detailed information regarding the function scope of the internal PLC is

available via the CIROS® on-line Help.

4.3

Controlling the process

models via internal PLC



If you are creating and testing your own PLC programs, we recommend

that you download the programs to an external PLC and execute them

from there. The advantage of this is that you can choose the PLC and

programming system of your choice. Also, the testing and diagnostic

functions designated by the program for this purpose are available to

you for fault finding in the PLC program. This includes the status display

of PLC input/outputs and variables, the on-line display of the PLC

program and also the read-out of machine statuses.

If you are using the Soft PLC S7-PLCSIM or CoDeSys SP PLCWinNT as

external PLC, you do not require any additional hardware components.

Information exchange with configuration via external Soft PLC S7-PLCSIM

4.4

Controlling the process

models via external PLC



If you are using a hardware PLC as external PLC, you will require

EasyPort and the data cable for the exchange of input/output signals.

EasyPort transmits the input/output signals of the PLC to the OPC

server ExOPC via the serial or the USB interface of the PC and the OPC

server passes on the data to the process model simulation. Conversely,

the statuses of sensors and actuators are communicated from the

process model to the external PLC.

Information exchange with configuration via external hardware PLC



The dialog window for fault setting is password protected. Only

instructors have access to this dialog.

A list of typical faults is available for each process model, from which

you can select one or several faults.

The exercise for students is to identify and describe the fault within the

process and to then determine the cause of it. The students then enter

the suspected fault in the dialog window for fault elimination. If the fault

has been correctly identified, the process will then function correctly.

The entries in the dialog window for fault elimination are logged and can

be seen by instructors and trainers.

4.5

Functions for fault setting

in the process model



CIROS® Mechatronics offers you various options of monitoring and

analysing the execution of a process.

As soon as the simulation of a process model is active and a PLC is

controlling the process, you can activate and visually monitor progress.

The process is controlled by means of the keys and switches on the

control console.

4.6

Functions for the analysis

of process models



The electrical status of the process components is displayed by LEDs

on the sensors and valves.

If pressure is applied to a cylinder connection, the connection is

highlighted in blue. The pneumatic tubing itself is not simulated.

The statuses of the PLC inputs/outputs are shown in separate

windows.

An overview of all process statuses and process operations is

provided in the Manual Operation window.

If you want to run the process step-by-step, you need to use the Manual

Operation as a tool to control the process. You can stop the process at

defined points by setting breakpoints.

In the absence of an active PLC program during process model

simulation, you can use the Manual Operation window to activate

individual process activities. This will enable you to, for instance,

control the movement of a cylinder or switch on or off an electrical

motor.


This chapter describes the main control functions of CIROS®

Mechatronics . MS Windows programs provides various options for

activating commands. In this account, commands are initiated via the

options in the menu bar. You can of course also use the symbols bar,

appropriate key combinations or the context sensitive menu via the

right mouse button.

Detailed information regarding the use of all options in CIROS®

Mechatronics is available via the on-line Help for this software package.

You can load preassembled process models with the help of CIROS®

Mechatronics Assistant or by using a menu bar command.

Process models of your own design or modified process models are

loaded solely via a menu bar command.

5. Important control functions of CIROS® Mechatronics

5.1

Loading a process model



This is how you load a process model via CIROS® Mechatronics

Assistant


Once CIROS® Mechatronics is started, both the View window and the

Help window are displayed.



2. In CIROS® Mechatronics Assistant, navigate to the directory with the

desired process model, for example to the Distrubuting Station

directory.

The process model is opened by clicking onto Open reference

model.



Open reference model means:

The write protected process model, filed in the CIROS® Mechatronics

program directory, is opened. The write protection ensures that the

correct functioning and simulation of the process model is ensured at all

times.

Open user model means:

The process model, previously copied to or filed as standard in your

personal folder under My Documents\CIROS\CIROS Mechatronics

Samples, is opened. Process models filed as user models are no longer

write protected. This therefore enables you to modify the associated

PLC programs and replaced these with your own. The directory with the

user models represents your individual working environment for CIROS®

Mechatronics.

Note



3. The process model for the Distributing station is loaded and is

displayed in the View window. In addition, you will also find the

status of the PLC input/outputs in the Inputs and Outputs windows.

Please note that the sample PLC programs do not use all the

displayed PLC inputs/outputs.

In the case of most process models, a table with the workpieces

possible is displayed as standard. If simulation is active, then you

select the workpiece you wish to use for the production process at

this table.



This is how you load a process model by activating a menu command

1. Click onto Open in the File menu.

The process models are filed under the default setting c:\Program

Files\Didactic\CIROS Automation Suite 1.1\CIROS

Mechatronics.en\Samples.

Each process model is in its own subdirectory.

2. Select the desired process model, for example the process model

Distributing. To do so, open the subdirectdory DistributingStation:

Highlight the directory DistributingStation and click onto the Open

button.



3. Highlight the file DistributingStation.mod and click onto the Open

button.



4. The process model for the Distributing station is now loaded and is

displayed in the View window.

In the case of most process models, a table with the workpieces

possible is displayed as standard. If simulation is active, then you

select the workpiece you wish to use for the production process at

this table.

If an error occurs when loading a process model, then please check the

entry for the rendering machine in the CIROS.ini file.

The rendering machine to increase graphics card performance must only

be activated if your PC has an appropriate graphics card and/or a

current graphics card driver is installed on your PC.

Note



Check the relevant entry regarding the rendering machine in the

CIROS.ini configuration file. The rendering machine ist not activated, if

the following setting is entered there:

[CIROS-Features]

ExternalRenderer=0

You will find the CIROS.ini file in the directory c:\Program

Files\Didactic\CIROS Automation Suite 1.1\CIROS

Mechatronics.en\Samples and for user models in C__Program

Files_Didactic_CIROS Mechatronics.en_bin under Documents and

Settings.



Once loaded, the process is displayed, but simulation is not active. A

table with the workpieces possible is displayed as standard for most of

the process models. If simulation is active, then select the workpiece

you wish to use for the production process at this table.

If the process model is to be simulated, a PLC program must be

available to control the running of the process model.

The PLC program can be executed in the internal S7 PLC or in an

external controller.

If you are working with a process model which was opened as a

reference model, then the sample PLC program for the process model is

automatically loaded to the internal PLC and executed when starting

simulation.

5.2

Simulating a process

model



If no PLC program is active, then the user can directly control individual

components by using the functions of the manual operation window.

As soon as simulation is active, you can monitor the visual simulation

and as such the function sequence of the process model in the activity

window.

Certain information is always available to you.

In the header you will see the file name with path details of the process

model loaded.

The status line informs you of the operational status of the process

model:

A field to the right displays whether simulation is active or stopped.

Stopped:

Simulation mode is not active. The process model is not simulated.

Cycle:

The process model is simulated.

Sequence:

The process model is simulated.

The field to the right indicates the simulation time.

In CIROS® Mechatronics , both simulation modes Cycle and Sequence

are identical.

Note



This is how you switch simulation on and off again

1. Make sure that the process model is in the initial position. You can

do this by executing the Reset Workcell command in the Simulation

menu.

2. Click onto Start in the Simulation menu.

Simulation is active. In the status bar, the simulation mode is

displayed via Running.

Alternatively, you can also activate simulation via the menu option

Start Cycle or via the Stopped button in the status bar.



3. You can stop simulation by clicking onto Stop in the Simulation

menu.

Alternatively, you can also click onto the Running field.

You can operate and observe the process model as soon as simulation

is active.



A process model controlled via a PLC program (as for example in the

case of the reference models) is operated via the keys and switches of

the control console. To do so, simulation must be active. The simulation

status can be established via the information in the status bar.

5.3

Displaying and operating

a process model



A table with the workpieces possible is displayed as standard for most

of the process models. If simulation is active, then you select the

workpiece you wish to use for the production process at this table.

This is how you operate a process model controlled via the sample PLC

program

(Reference models are controlled via sample PLC programs)

1. Start simulation by clicking onto Start in the Simulation menu.

2. The illuminated Reset button now requests the Reset function.

Failing this, put the process model into the initial position. To do so,

activate the simulation. Then click onto the command Reset

Workcell in the Simulation menu.

Now restart simulation.

3. Carry out the Reset function by clicking onto the Reset button.



4. The illuminated Start button indicates that the process model is in

the initial position and the start condition is fulfilled.

5. Make sure that workpieces are available. In the case of the

Distributing process model this means: the magazine of the

distributing station must be filled with workpieces.



6. Click onto the desired workpiece on the table with the workpieces.

All workpieces are realised in the form of buttons. The selected

workpiece, a red basic cylinder body, is shown as "pressed".

Now click onto the symbolic workpiece on the distributing station.

With each mouse click, the magazine is filled with the selected

workpiece.

7. Start the cycle by clicking onto the Start button.



If the process model is to be controlled via your own PLC program, then

you will know how the process and operation are defined.

If the process model is not controlled via a PLC program, then you can

manually activate specific actuators of the process. You will need the

functions of the Manual Operation window for this.

This is how the status of the process model is displayed

The electrical status of the process components is displayed via the

LEDs on the sensors and valves.

If pressure is applied to a cylinder connection, then this connection

is highlighted in blue.

The pneumatic tubing itself is not shown.

The status of the PLC signals is displayed in the Inputs and Outputs

windows.

The Manual Operation window provides an overview of all process

statuses and process events.

The designation of components is shown by clicking onto the

connection or LED of a process component. This designation is

identical to the designation in the circuit diagram.

An exception to this is the designations of compressed air

connections. These pertain to the valves which supply the

compressed air connections with air.



The perspective view of a process model is freely adjustable and you

can turn, move, enlarge or minimise the process model representation

by means of a few central commands.

5.4

Changing the view of a

process model



The perspective view is defined by the coordinates of the viewer (=

angle) and a reference point of the process model (= centre).

ZReference point

AngleTurn

Y

X

Definition of perspective view



This is how you move the process model

1. Click onto the Move command in the View menu.

This changes the mouse pointer into a small coordinate system,

which indicates the direction in which the angle and reference point

can be moved. A dashed arrow means that it is not possible to move

in the respective direction.

2. Hold down the left mouse button.

3. Move the mouse pointer in Z- or X-direction.

4. Release the mouse pointer again. The view will then change

accordingly.

You can also activate the Move command by holding down the Shift key

and pressing the left mouse button.

This is how you turn the process model

1. Click onto Turn in the View menu.

The mouse pointer now changes into a small coordinate system,

which indicates the direction in which the angle and reference point

can be moved. A dashed arrow means that it is not possible to move

in the respective direction.

2. Hold down the left mouse button.

3. Move the mouse pointer in Z-or X-direction.

4. Release the mouse pointer again.

The view will then change accordingly.

You can also activate the Turn command by holding down the Ctrl key

and then pressing the left mouse button.

This is how you enlarge or minimise the view

1. Activate the Zoom command in the View menu.

The mouse pointer now changes into two squares.

2. To enlarge the view, hold down the left mouse button and move the

mouse pointer in the direction of the arrow.



3. To minimise the view, hold down the left mouse button and move

the mouse pointer in the opposite direction of the arrow.

You can also activate the Zoom command by holding down the Shift +

Ctrl key combination and then pressing the left mouse button.

If you have a mouse with a scroll wheel, you can easily enlarge or

minimise the process model view by using the scroll wheel.

This is how you enlarge a particular section

1. Position the mouse pointer on a corner of the section.

2. Hold down the Shift + Ctrl key combination.

3. Press the right mouse button and move the mouse. A frame is then

displayed.

4. Place the frame around the section you would like to enlarge by

moving the mouse.

5. Release the right mouse button. The view is now enlarged.

This is how you enlarge the view

Click onto Zoom-In in the View menu. The image is now enlarged to

125%.

This is how you minimise the view

Click onto Zoom-Out in the View menu. The picture is minimised to

80%.



The Inputs and Outputs windows indicate which signals are applied at

the inputs and outputs of the PLC. 0-signals are displayed in red and

1-signals in green. If the input or output signal is forced, the value is

shown in angle brackets, e.g. <1>.

This is how you open the Inputs window

Click onto the option Inputs/Outputs in the View menu and select Show

Inputs.

So that you know which process signal you are dealing with, the signal

names include the relevant designation from the circuit diagrams.

Example: STATION_1B2: PLC input, which is connected to the sensor

1B2.

This is how you open the Outputs window

Click onto the option Inputs/Outputs in the View menu and select Show

Outputs.

So that you know which process signals you are dealing with, the signal

names contain the relevant designations from the circuit diagrams.

Example: STATION_1M1: PLC output, which is connected to the valve

coil 1M1.

5.5

The Inputs and Outputs

windows



You can however also open the Inputs and Outputs windows via

Workspaces in the Window menu, where you will often find the

required window combinations.

The Manual Operation window offers various functions

Display of process statuses and process activities,

Controlling individual actuators of the process model,

Setting breakpoints in the process model simulation.

In the lefthand section of the window you can see the process activities.

These include mainly the actuation of valves. An applied 1-signal is

represented by a red illuminated LED.

In the righthand section of the window you can monitor all process

statuses.

Process statuses include the status of the sensor and valve coils. Here,

1-signals are represented by a green illuminated LED.

The signal statuses are also shown in the Value column. If the signal is

forced, the value is shown in angle brackets. If the Value column is now

shown, activate the item in the context sensitive menu via the right

mouse button.

Notes

5.6

The Manual Operation

window



The following additional information is displayed: If a signal status has

changed since the last simulation cycle, then the respective line is

highlighted in colour. Process activities are shown in red and process

statuses in green. This method enables you to easily identify and track

any signals which have changed.

This is how you open the Manual Operation window

In the Modeling menu, click onto Manual Operation.

Alternatively , open the window by clicking onto Manual Operation

under Workspaces in the Window menu.

This is how you control individual actuators in the process model

If you want to actuate individual actuators of a process model manually,

we recommend that you disconnect the process model from the PLC.

Only those commands will then be executed which have been initiated

via manual operation since the PLC program is no longer active.

If you wish to terminate manual operation and control the process

model via a PLC program once again, you will need to reconnect the

process model to the PLC.



1. Make sure that simulation is stopped.

2. Isolate the process model from the PLC.

Move the mouse pointer to the left section of the Manual Operation

window and the process activities. Press the right mouse button to

open the context sensitive menu and select Disconnect all

Controllers.

3. Start the simulation.



4. Double click onto the process activity line you wish to execute. The

double click causes the signal to change.

If you double click onto a line with a valve activation, this causes the

value of the respective valve coil to change. If the value 0 is applied,

this will be set to 1 or vice versa. The double click therefore has a

toggle function.

Please note: To switch a valve with two valve coils to a particular

position, the appropriate electrical signal must be applied to both

valve coils.

5. Stop simulation, if you wish to end Manual Operation.



6. To control the process model via a PLC program again, move the

mouse pointer to the left section of the Manual Operation window

to the process activities. Now press the right mouse button to open

the context sensitive menu and select Restore I/O Connections.



This is how you set breakpoints during the operation of the process

model

To stop the process model operation at defined points, you will need to

set breakpoints in the process model simulation. You can stop the

process run whenever the value of a process signal is changing.

Breakpoints merely influence process model simulation; the PLC

program for the control of the process model remains unaffected. If a

breakpoint is set at a signal, this causes the process model simulation

to stop when the value of the signal changes. The changed value is

transmitted to the PLC as soon as simulation is restarted.

1. Make sure that a process model is loaded.

2. Start the process model simulation and establish that the process

model is controlled via a PLC program.

3. Open the Manual Operation window. To do so, click onto Manual

Operation in the Modeling menu.



4. Click onto the line of the desired process activity. In this case, for

example, line 1 to control valve coil 1M1 for the magazine ejector.

Click onto the right mouse button to open the context sensitive

menu and select Stop at Value Change.



5. The Stop sign in the line in the Manual Operation window indicates

that a breakpoint is set at this signal.



6. Activate the process. As soon as the PLC generates a 1-signal at the

valve coil 1M1, simulation stops. You can follow the simulation

status in the status bar.

7. If you restart simulation of the process model, this causes the

process run to continue and the magazine ejector to eject a

workpiece.



8. To delete the breakpoint, click onto the line with the breakpoint with

the right mouse button. This opens the context sensitive menu of

the right mouse button. Select Stop at Value Change. This command

is realised in the form of a toggle function. The breakpoint is

removed. Alternatively, you can select the command Delete all

Stops.

Please note that you can also set breakpoints at signals in the Process

Status window section.



This is how you control the process model step-by-step

If you want to execute the process stepwise, then use the Manual

Operation window as a tool to control simulation. You can stop the

process at defined points by setting breakpoints.

To execute the process step-by-step, set breakpoints against all process

activities. In this way, the process will be stopped whenever an actuator

changes its status.

1. Make sure that a process model is loaded.

2. Make sure that the process model is controlled via a PLC program.

3. Open the Manual Operation window. To do so, click onto Manual




4. Under Process Activities, highlight all lines containing signals for

valve coils by pressing the Ctrl key and clicking onto the desired

lines with the left mouse button.

Open the context sensitive menu via the right mouse button and

select Stop at Value Change.



5. All lines with valve coils now indicate breakpoints.

6. Start the simulation and control the process by using the keys and

switches of the control console. Whenever the status of a process

signal changes, simulation stops. The process is continued if you

restart simulation.



7. To remove the breakpoints again, open the context sensitive menu

via the right mouse button and select Delete all Stops.

Please note that you can also set breakpoints at signals in the Process

Status window section.



The internal S7 simulator interprets executable S7 programs. A sample

PLC program for S7-300 is available for each of the more complex

process models. When you load a model, the respective S7 program is

also downloaded. You can exchange this S7 program with another S7

program, if required.

Only complete project files with the file extension S7P can be

downloaded. The project will need to have been created via the SIMATIC

Manager and must be in accordance with the Siemens MC7 code at

binary level.

5.7

Controlling a process

model via the internal

S7 PLC



This is how you control a process model via the relevant sample PLC

program

1. Make sure that the Help window of CIROS® Mechatronics Assistant

is open. You open CIROS® Mechatronics Assistant by activating the

command Workcells of CIROS® Mechatronics in the Help menu.

2. In CIROS® Mechatronics Assistant, navigate to the directory with the

desired process model, for example to the directory Distributing

Station.

The process model is loaded by clicking onto Open reference model.

3. As soon as simulation of the process model is started, the execution

of the S7 is also started.

To do so, click onto Start in the Simulation menu.



This is how you control a process model via a newly created S7 PLC

program

1. Load the desired process model. The process model is to be

controlled via the internal PLC. As the PLC program is to be modified,

load a user model at this point.

The process model is to be controlled via the internal PLC. The

setting via which the PLC is to be controlled can be seen in the

Switch external PLC <-> internat PLC window. You will find the

command to activate this window in the Modeling window. The

entry S7-PLC Simulator in the Type column means: the process

model is controlled via the internal S7-PLC. Close the window Switch

external PLC <-> internal PLC again.



2. Make sure that simulation has stopped.

3. Select Open in the File menu to open the Open File window.

4. Under File Type, select S7 Project (*.S7P).

All files of this format available in the current directory are

displayed.



5. Navigate to the directory which contains your S7 project.

Select the required S7 project and click onto the Open button.

6. If the project you have selected contains several S7 programs, then

select one for simulation and confirm your choice with OK.



7. Start the process model simulation. Select Start in the Simulation

menu. As soon as the simulation of the process model is started, the

internal S7 simulator is also started and the loaded PLC program is

executed.

This is how you establish which S7 program is currently loaded

1. Click onto the S7 Program Manager option in the Programming

menu.

2. The name and the structure of the PLC program are displayed in a

clearly set out tree structure.

The PLC program may consist of the following blocks: Organisation

blocks, function blocks, data blocks, functions and system

functions.



3. Click onto the +-symbol to display the PLC program.

You can view the contents of a block by clicking onto a block.

4. In the absence of a loaded PLC program, the window S7 Program

Manager looks as follows:

Further information regarding the display of S7 programs in STL or for

the display and use of timing diagrams is available via the on-line Help.



This is how the sample programs are filed on the computer

1. Select Open in the File menu to open the Open File window.

2. Under File Type, select S7 Project (*.S7P).

All the files in this format available in the current directory will be

displayed.



3. The sample programs for the reference models are filed in the

program directory of CIROS® Mechatronics.

Navigate to the directory c:\Program Files\didactic\CIROS

Automation Suite 1.1\CIROS Mechatronics.en\

samples\S7\MPSC_V22. This directory contains the S7 project with

all the sample PLC programs for the MPS C stations, provided that

you have transferred all the preset directories when installing

CIROS® Mechatronics. The sample program for the stacker store is

stored in the Store subdirectory. The other subdirectories contain

the sample programs for the MPS B stations for the Conveyor project

module and a sorting system.

A comparable directory structure is set up for the user models. The

user models are stored as standard under My

Documents\CIROS\CIROS Mechatronics Samples.



4. Select the S7 project and click onto the Open button.

The program name provides information about the PLC program and the

process model to which it belongs:

The initial digit corresponds to the station number.

The two letters after this digit designate the station:

DI: Distributing station

TE: Testing station

PR: Processing station

HA: Handling station

BU: Buffer station

SO: Sorting station

PP: Pick and place station

FM: Station Fluidic Muscle Press

TR: Separating station

The letters beginning with underscore designate the programming

language of the PLC program:

AS: Programming language GRAPH,

KFA: Programming languages LDR, FCH and STL,

KFAFF: Programming languages LDR, FCH and STL. The step

structure of the process activity is simulated with flipflops.



The internal PLC supports to a large extent the command set of the S7-

400 controllers, whereby the programs can be created in ladder

diagram, function chart, statement list or in the form of graphic

sequence control.

S7-PLCSIM is a Soft PLC, which executes the PLC programs created in

STEP 7. Within STEP 7, comprehensive testing and diagnostic functions

are available to you for fault finding in the PLC program. They include,

for instance, the status display of variables or the on-line display of the

PLC program. You can make use of these functions when creating the

PLC program for a process model in STEP 7 and subsequently when

testing the PLC program during interaction with the process model.

The exchange of the PLC input/output signals between the process

model simulation and the Soft PLC S7-PLCSIM is effected via the EzOPC

program. The EzOPC program forms part of the CIROS® Automation

Suite and has been installed on your PC together with the CIROS®

Mechatronics application.

EzOPC is automatically invoked by CIROS® Mechatronics as soon as you

start simulation of a process model and this process model is to be

controlled via an external PLC.

If you work with the operating system Vista, please make sure that the

used S7-PLCSIM-Version is Vista compatible.

5.8


model via the external

Soft PLC S7-PLCSIM

Note



The following requirements must be fulfilled in order for the PLC

input/output signals to be correctly exchanged:

When EzOPC is started, both communication users ‟ S7-PLCSIM and

the process model simulation- must already be active. Only then can

EzOPC set up the communication link to both stations.

The EzOPC must be correctly configured for the data exchange.

Therefore check the configuration as soon as EzOPC is started.

Configuration of EzOPC for data exchange with S7-PLCSIM



This is how you control a process model with S7-PLCSIM

1. Start STEP 7 or the STEP 7 Manager and open the required

S7 project.

2. Start S7 PLCSIM by clicking onto Simulate Modules under Options.

3. The S7-PLCSIM window now opens.

4. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto

the MRES button in the CPU 300/400 window.



5. Download the desired PLC program in S7-PLCSIM by highlighting the

Modules folder. Then click onto Download in the menu Target

System.



6. Load the appropriate process model in CIROS® Mechatronics.

7. Select the setting for the process model to be controlled via an

external PLC by activating the command Switch external PLC <->

internal PLC in the Modeling menu.



8. The Switch external PLC <-> internal PLC window opens. The

information regarding process model control is displayed in the

columns Type and Program Name/OPC Server.

- The name of the process model is Distributing.

- The process model is controlled via the internal PLC. You can

establish this by the item S7 PLC-Simulator.

- The internal PLC executes the PLC program. The PLC program forms

part of the STEP 7 project MPSC_V22.s7p, using the path specified.

9. Highlight the entry for the process model. Activate the context

sensitive menu of the right mouse button. Select the Switch

command.

Alternatively switch the controller by double clicking onto the item.



10. OPC Server is now entered in the Type column for the process

model. The server name FestoDidactic.EzOPC.2 is displayed under

Program Name/OPC Server. This entry means that the process

signals for the Distributing process model are exchanged via an OPC

server with the name FestoDidactic.EzOPC.2.

11. Close the Switch external PLC <-> internal PLC window.

12. Check whether the process model is to be in the initial position. If

yes, then activate the Reset Workcell command in the Simulation

menu.



13. Start the process model simulation by clicking onto Start under

Simulation.

As soon as simulation starts, the EzOPC program is automatically

called up and you will see this from the item EzOPC displayed in the

Start bar.

When EzOPC is started, both communication users - S7-PLCSIM and the

process model simulation ‟ must already be active. Only then are the

communication links correctly set up.

Note



14. Click onto the EzOPC button in the Start bar. This opens the EzOPC

window, where you configure the communication between CIROS®

Mechatronics and S7-PLCSIM.

The overview indicates that CIROS® Mechatronics is connected to

S7 PLCSim via the virtual controller of EzOPC. The table shows which

components are installed individually and whether EzOPC is in the

process of accessing this component.

Make sure that the communication links of your EzOPC are

configured as shown below. The desired communication links are

established by clicking onto the appropriate button.



15. Now click onto the Virtual Controller register where the virtual

controller status and your inputs/outputs are displayed. 8 input

bytes and 8 output bytes are preset for data exchange. You can

accept this presetting unaltered.

If a 1-signal is applied to an input/output byte bit, then this is shown

illuminated.



16. Click onto the S7-PLCSIM register and check the settings. Here, the

status of S7-PLCSim simulation and its inputs/outputs is displayed.

8 input bytes and 8 output bytes are preset for data exchange. You

can accept this presetting unaltered. However, only the first 4 bytes

are required.

If a 1-signal is applied to an input/output byte bit, then this is shown

illuminated.

17. Minimise the EzOPC window.

18. Make sure that the process model simulation in CIROS®

Mechatronics is active.



19. Start S7-PLCSIM by clicking onto the box next to RUN in the window

CPU 300/400. The LED for RUN should now start flashing.

20. Operate the process model as planned and programmed in the PLC

program.

21. If faults still exist in the PLC program, then the on-line

representation in STEP 7 will provide you with excellent support

during fault finding. To do so, call up the program block in which you

suspect the fault. Then click onto Monitor in the Test menu. You can

now monitor in parallel with simulation, which PLC program sections

are or are not being executed.



CoDeSys SP PLCWinNT is a Soft PLC which executes the PLC programs

created in CoDeSys.

The PLC input and output signals are exchanged between the process

model simulation and the Soft PLC CoDeSys SP WinNT via the EzOPC

program. EzOPC is part of the CIROS® Automation Suite, and will have

been installed on your PC together with the CIROS® Mechatronics

application.

CIROS® Mechatronics automatically starts up EzOPC as soon as the

simulation of a process model begins if the process model needs to be

controlled via an external PLC.

If you are using the MS Windows Vista operating system, ensure that

the version of CoDeSys SP PLCWinNT which you are using is Vista-

compatible.

5.9


model via the external

Soft PLC CoDeSys SP

PLCWinNT

Note



The following requirements must be fulfilled in order to ensure that the

PLC input and output signals are exchanged correctly:

There must be an interface to the OPC server EzOPC in the CoDeSys

PLC program. The input and output signals of the PLC program are

transferred byte by byte via this interface.

The UNPACK functional module and the PACK function in CoDeSys

can be used to convert bits to bytes.

Program execution in CoDeSys SP PLCWinNT

OPC_notUsed

OPC_notUsed

OPC_notUsed

OPC_notUsed

OPC_notUsed

OPC_1B2

OPC_2B1

OPC_3B1

B B0

B1

B2

B3

B4

B5

B6

B7

UNPACK (FB)

OPC_notUsed

OPC_notUsed

OPC_notUsed

OPC_notUsed

OPC_notUsed

OPC_notUsed

OPC_notUsed

OPC_P2PACKB0

B1

B2

B3

B4

B5

B6

B7

PACK (FUN)PLC program

&OPC_1B2

OPC_2B1

OPC_3B1

OPC_P2

EzOPC

CIROS

Process modelsimulation

®

EB0 AB1

Process outputs(Actors)

Process inputs(Sensors)

Simple program example of OPC interface in CoDeSys



When starting EzOPC, both communication users – CoDeSys SP

PLCWinNT and the process model simulation in CIROS® – must

already be active. Only then can EzOPC set up the communication

link to both users.

The EzOPC program must be correctly configured for data exchange.

In order to ensure this, check the configuration as soon as EzOPC

starts up.

Configuration of EzOPC for data exchange with CoDeSys SP PLCWinNT



This is how you control a process model with CoDeSys SP PLCWinNT

1. Start CoDeSys and open the desired CoDeSys project.



2. Make sure that the Util.lib library is entered in the Resources tab.

If this is not the case, add the Util.lib library using the Library

Manager: Double-click on Library Manager in the Resources tab. In

the Insert menu, select Additional Library. Find the location where

Util.lib is stored. The default location for the library is in the

directory c:\Program Files\3S Software\CoDeSys\Library.

Once you have selected the Util.lib library, click on the Open button.

Close the Library Manager window.

3. Next, define the input/output signals to be exchanged with the

CIROS process model via the OPC interface. The input/output

signals in the example project can be easily identified by the

extension OPC. The input/output signals are defined as global

variables.

You can open the Global_Variables window by opening the Global

Variables folder in the Resources tab, then double-clicking on

Global_Variables.



4. Expand the control program by calling up the UNPACK functional

module. This extracts the EB0 input byte and converts it into

8 Boolean variables. In the example project, only bits 1, 3 and 4 of

the EB0 input byte are needed.

Remember that an instance (Unpack_EB0 in the example) must be

defined in the program head before a functional module can be

called up.

5. Expand the control program by calling up the PACK function. The

PACK function combines 8 Boolean variables into one byte. In the

example, the PACK function shows the output signal OPC_P2 on bit

1 of output byte AB1.



6. Make sure that the Soft PLC CoDeSys SP PLCWinNT is set as the

target system for the project. To do this, double-click on Target

Settings in the Resources tab. 3S CoDeSys SP PLCWinNT must be

set as the configuration.

7. Next, configure the settings in CoDeSys for the data exchange

between CoDeSys SP PLCWinNT and CIROS® Mechatronics. To do

this, open the Start menu, go to 3S Software -> Communication and

select CoDeSys OPC Configurator.



8. Set Single PLC for OPC communication. Do this by selecting Single

PLC in the File menu.

9. In the tree structure, click on Server and set an Update Rate of 100

for the OPC server. Alternatively, you can also use the preset value.



10. In the tree structure, click on PLC and enter the name of the PLC

project.

Note

The project name must exactly match the name of the CoDeSys

project file. If the project is changed, the name must also be

changed here to match.



11. In the tree structure, click on Connection to specify the type of

connection between the OPC server and the Soft PLC. As both

programs run on the same computer, select the Local option for

Gateway. Select Tcp/lp with the Address localhost as the Device

for the new connection.

Configure the settings in the Communication Parameters window.

12. Open the Communication Parameters window by clicking on the

Edit button. Then click on the Gateway button and select Local as

the connection for Gateway.



13. Click the New button to define the parameters for the new

connection channel. Enter the name of the channel and select

Tcp/lp as the device.

14. Close the window Communication Parameters: New Channel.

15. Close the windows Communication Parameters and OPCConfig.



16. Next, prepare the input/output bytes which are to be transferred

via the OPC interface for data exchange. To do this, activate the

Options command in the Project menu in CoDeSys. In the Options

window, click on Symbol configuration.



17. Select Dump symbol entries, then click on the configure symbol

file button.

This opens the Set object attributes window.



18. Open the Global Variables folder and select the objects AB1

(BYTE) and EB0 (BYTE). Hold down the Ctrl key while selecting.

Place a tick in each check box and close the Set object attributes

and Options windows.

19. Click on the Rebuild all command in the Project menu.

20. Start CoDeSys SP PLCWinNT by selecting it from the Start menu.



21. The CoDeSys SP PLCWinNT window opens.

22. To establish the connection between the CoDeSys programming

system and the Soft PLC CoDeSys SP PLCWinNT, activate the Login

command in the Online menu in CoDeSys.



23. If the current project is different to the PLC program in the Soft

PLC, you will be asked whether you wish to load the current PLC

program when you log in. Click Yes.

The current project is loaded into the Soft PLC.



24. Load the corresponding process model in CIROS® Mechatronics.

25. Alter the process model settings so it is controlled by an external

PLC. To do this, go to the Modeling menu and activate the Switch

external PLC <-> internal PLCcommand.



26. The Switch external PLC <-> internal PLC window opens. The Type

and Program Name/OPC Server columns show information on

how the process model is controlled.

‟ The name of the process model is Distributing.

‟ The process model is controlled by the internal PLC. You

can see this from the S7 PLC Simulator entry in the Type

column.

‟ The internal PLC executes the PLC program. The PLC program is

part of the STEP 7 project MPSC_V22.s7p with the specified

path.

27. Highlight the process model entry. Click the right mouse mutton to

open the context-sensitive menu. Select the Switch command.

Alternatively, you can switch the control system by double-clicking

on the entry.



28. The Type column now shows OPC Server for the process model.

The Program Name/OPC Server column now shows the server

name FestoDidactic.EzOPC.2. This means that the process signals

for the Distributing process model are exchanged via an OPC

server with the name FestoDidactic.EzOPC.2.


30. Check whether the process model is meant to be in the basic

setting. If so, activate the Reset Workcell order in the Simulation

menu.



31. Start the simulation of the process model. To do this, open the

Simulation menu and select Start.

As the simulation starts, the EzOPC program is automatically

opened. You can see this because EzOPC appears in the start bar.

When starting EzOPC, both communication users – CoDeSys SP

PLCWinNT and the process model simulation – must already be active.

Only if this is the case will the communication links be correctly set up.

Note



32. Click on the EzOPC button in the Start bar. The EzOPC window

opens. Here you can configure the communication between

CIROS® Mechatronics and CoDeSys SP PLCWinNT.

The overview shows that CIROS® Mechatronics is connected to the

CoDeSys control system via the EzOPC virtual control system. The

table shows details of which components are installed whether

EzOPC directly accesses these components.

Make sure that the communication links of your EzOPC are

configured as shown below. You can create the desired

communication link by clicking the corresponding button.



33. Next, click on the Virtual Controller tab. This displays the status of

the virtual controller and its I/Os. 8 input bytes and 8 output bytes

are preset for data exchange. You can use this preset without

modifying it.

If logic 1 applies to any bit of the input/output byte, this bit is

represented by a brighter colour.



34. Click on the CoDeSys tab and check the settings. This tab shows

the status of the CoDeSys SP PLCWinNT simulation and its

inputs/outputs. 8 input bytes and 8 output bytes are preset for

data exchange. You can use this preset without modifying it.

However, only the first 4 bytes are required.

If logic 1 applies to any bit of the input/output byte, this bit is

represented by a brighter colour.


36. Make sure that the process model simulation is active in CIROS®

Mechatronics.



37. Start running the PLC program in the Soft PLC. To do this, open the

Online menu and click Run.

You can see the current status of the Soft PLC CoDeSys SP

PLCWinNT in the CoDeSys SP PLCWinNT window.

38. Operate the process model as you specified and programmed in

the PLC program.



If you are creating and testing your own PLC program, we recommend

that you download the programs to an external PLC and have these

executed from there.

You can use the Soft PLC S7-PLC SIM as external PLC, if you are

programming in STEP 7, in which case you will not require any

additional hardware components.

You can however also use any other control or programming system, in

which case you download the PLC program to your hardware PLC. The

exchange of the PLC input/output signals between the process model

simulation and your external PLC is effected via the serial or the USB

interface of the PC and via the EasyPort interface. Also included in the

exchange of process signals is the EzOPC program.

The advantage of this configuration is that you can use the PLC and

programming system of your choice. Also available for fault finding in

the PLC program are the testing and diagnostic functions intended for

this purpose in the programming system.

We recommend that you install the simulation software CIROS®

Mechatronics and the PLC programming system on different computers.

5.10


model via an external PLC



Possible configuration with a hardware PLC and two PCs



However, you can also choose a different configuration and install the

two software packages on one PC. Your PC will need to be equipped

with two serial interfaces or with one serial and one USB interface if you

intend to make use of the testing and diagnostic functions during the

process model simulation .

The following can be used as EasyPort interface:

EasyPort D16 interface box for 16 digital I/O (Order No.. 167121)

The following data cables are required:

PC data cable RS232 for EasyPort with PC to RS232 (Order No. 162

305) or

USB adapter RS232 for EasyPort with PC on USB (Order No. 540699)

For PLC EduTrainer of Festo Didactic: I/O data cable with SysLink

plugs at both ends to IEEE 488, cross paired (Order No.. 167 106)

For any PLC: I/O data cable with SysLink plug at one end to IEEE 488

and open cable end sleeves (Order No. 167 122)

The EzOPC program

The EzOPC program organises the exchange of PLC input/output signals

between the process model simulation and the external PLC. EzOPC

does not access the external PLC signals directly, but via the EasyPort

interface.

The EzOPC program forms part of the CIROS® Automation Suite and has

been installed on your PC in conjunction with the CIROS® Mechatronics

application. EzOPC is invoked automatically by CIROS® Mechatronics as

soon as you start the simulation of a process model and this process

model is to be controlled via an external PLC.



The following requirements must be fulfilled in order for the PLC

input/output signals to be correctly exchanged:

When starting EzOPC, both communication users ‟ EasyPort and the

process model simulation - must be active. Only then can EzOPC set

up the communication link to the two users.

In the case of EasyPort this means that EasyPort must be connected

to the PC via the serial interface and voltage applied to EasyPort.

The EzOPC program must be correctly configured for the data

exchange. Therefore check the configuration as soon as EzOPC is

started.

Configuration of EzOPC for data exchange with an external PLC via EasyPort



This is how you control a process model via an external PLC

1. Connect the PC with CIROS® Mechatronics to the external PLC via

the EasyPort interface.

‟ The data cable with Order No. 162 305 connects the serial

interface of the PC to the serial interface RS232 of EasyPort.

If you are using the USB interface, then use the data cable of

Order No. 540699.

‟ The PLC input/output signals for the process are applied at port 1

of EasyPort.

‟ The PLC input/output signals for the control console are

transmitted via port 2.

‟ If you are using EasyPort without USB interface:

For the DIP switches under Mode at EasyPort, select the

following setting: 1 ON, 2 OFF, 3 OFF.

‟ If you are using EasyPort with USB interface:

Make sure that address 1 is set for EasyPort.

The set address can be read or changed by pressing the two arrow

buttons. Simultaneously pressing both buttons stores the address

and exits address mode.



Configuration with PLC EduTrainer



Configuration with PLC board



2. Switch on the power supply for EasyPort.

3. Load the desired process model to CIROS® Mechatronics.

4. Effect the setting for the process model, i.e. that this is to be

controlled via an external PLC. To do so, activate the command

Switch external PLC <-> internal PLC in the Modeling menu.



5. The window Switch external PLC <-> internal PLC now opens which

displays the information regarding the process model control in the

columns Type and Program Name/OPC Server.

The name of the process model is Distributing.

− The process model is controlled via the internal PLC. You can see

this by the entry S7 PLC simulator.

− The internal PLC executes the PLC program. The PLC program

forms part of the STEP 7 project MPSC_V22.s7p with the specified

path.

6. Highlight the entry for the process model. Activate the context

sensitive menu of the right mouse button and select the command

Switch.

Alternatively switch the controller by double clicking onto the entry.



7. OPC Server is not entered for the process model in the Type column.

The server name FestoDidactic.EzOPC.2 is displayed under Program

Name/OPC Server. This entry means that the process signals for the

process model Distributing are exchanged via an OPC server named

FestoDidactic.EzOPC.2.


9. Check whether the process model is to be in the initial position. If

yes, then activate the command Reset Workcell in the Simulation

menu.



10. Start the simulation of the process model by clicking onto Start

under Simulation.

The EzOPC program is called up automatically when simulation

starts. You will see EzOPC displayed in the Start bar.



When EzOPC is started, both communication users - EasyPort and the

simulation of the process model ‟ must already be active. Only then can

the communication link be correctly set up.

11. Click onto the EzOPC button in the Start bar to open the EzOPC

window, where you configure the communication between CIROS®

Mechatronics and EasyPort.

Note



12. The overview shows that CIROS® Mechatronics is connected to S7

PLCSim via the virtual controller of EzOPC.

You will need a communication link between CIROS® Mechatronics

and EasyPort. Click onto the PLC via EasyPort button to establish

this.



13. The configuration link between CIROS® Mechatronics and EasyPort

is configured.

The table indicates which components are installed and whether

EzOPC is currently accessing these components.



14. Now check the range of inputs/outputs via which data exchange is

to be effected in the virtual controller. To do so, click onto the

Virtual Controller register.

8 input bytes and 8 output bytes are preset for data exchange. You

can accept these presettings unaltered. Only the first 4 bytes are

required.



15. Click onto the EasyPort register where the status of the connected

EasyPort and its inputs and outputs are displayed. If a 1-signal is

applied to an input/output byte bit, then this is shown illuminated.


17. Download the PLC program to the PLC.

18. Start up the PLC.

19. Start the process model simulation.

20. Operate the process model according to how you have planned and

programmed it in the PLC program.



Use the Fault Setting window to set specific faults in the functional

sequence of a process model. Use the internal PLC and the sample PLC

program provided to control the process model. This ensures that a

potential fault behaviour is caused solely by process components. The

PLC program is operating error-free.

The setting of faults is permissible by authorised users only. This is why

the dialog for fault setting is password protected. The default for the

password is didactic. The password can be changed at any time.

Each process model contains a list of possible faults.

5.11

Setting faults in a

process model



The following data is required if you want to generate a fault for one of

the listed process components

Type of fault

Start of fault

Duration of fault

With some components, different faults can occur and you can select

these faults from a list of options.

The following mean:

Reed switch displaced: Reed Switch is mechanically displaced.

Reed switch jammed: A 1-signal is continually applied at the reed

switch.

Cable break: A 0‟signal is continually applied at a component.

Short circuit - voltage: A 1-signal is continually applied at

component.

Malfunction: Complete failure of component.

Tubing defective: Pneumatic tubing is defective, operating pressure

not achieved.

Compressed air supply malfunction: Pressure failure.

Power supply malfunction: Voltage not available.

The time stated for the start of malfunction refers to the simulation time

after the fault is set.

The duration of the fault is to be indicated in seconds.

Error statuses influence the simulation of the process model as soon as

the Fault Simulation is active.

Only in user models fault functions are stored if the process model is

stored. The fault functions remain active until they are deactivated in

the Fault setting window.

Note



This is how you set faults in the process model

1. Make sure that a user model is loaded. The process model is to be

controlled via the internal PLC.

2. Open the Fault Setting window by activating Fault Setting in the

Extras menu under Fault Simulation.

You can also open the Fault Setting via Window Workspaces Teacher

mode. Under Teacher mode are frequently-needed window

combinations for the Fault operation.

Note



3. A dialog box is displayed for the password to be entered.

Enter the password. Provided that you have not changed the

password since CIROS® Mechatronics has been installed, then the

standard specified password is still valid.

Enter didactic in the Password box.

Note that the password is case-sensitive.

Confirm your entry with OK.

4. The Fault Setting window is now displayed.



5. Set a fault function ‟ for example for the PLC input 1B1.

Double click onto the appropriate field in the Type column to display

a list of options. Open the list and select the type of fault, e.g. Cable

break.

The fault is to become active with the start of simulation and to

remain so until the fault is cancelled in Fault Setting. No entry is

therefore required in the Begin column field.

The duration of the fault is arbitrary and likewise, no entry is

therefore required in the Duration column.

Entries in the Begin and Duration column are activated by means of

a double click.



6. The selected faults are displayed in the Status column.



7. Now activate the Fault Simulation mode by selecting Fault

Simulation in the Extras menu under Fault Simulation.

8. Close the process model in order to deactivate the teacher mode.

This is how you start the simulation of the process model with the set

faults

1. Open the process model with the set fault.

2. Make sure that Fault Simulation is activated.

3. Start the process model simulation.



Use the Fault Localisation window to eliminate error functions in the

process model. The set error functions only occur if the process model is

controlled via a PLC program and if the Fault Simulation mode is active.

Distributing process model: The process activity stops once a workpiece

is ejected. The next step, moving the swivel arm into the magazine

position, is not executed.

When monitoring and analysing the process model simulation, you

realise that voltage is applied to the sensor 1B1, but not to the

respective PLC input. You therefore conclude that there is a cable break

at the PLC input 1B1.

5.12

Eliminating faults in a

process model

Example



This is how you eliminate a fault in the process model

1. Make sure that the process model is loaded.

2. Open the Fault Localisation window by clicking onto the Fault

Localisation window in the Extras menu under Fault Simulation.



3. The Fault Localisation window is displayed.



4. In the line 1B1 PLC input, double click onto No fault and select Cable

break in the list.

The button is now illuminated in yellow.

If the fault Is correctly identified, the next process model simulation

will be executed fault-free.



5. In teacher mode, the Fault Localisation window looks as follows:

If you have correctly identified and entered the fault, the process

model is executed correctly in the next simulation cycle.

If you have failed to correctly identify the cause of the fault, then the

fault remains in place.

If you have erroneously identified the cause of the fault as a

mechanically displaced sensor, then you have created an additional

fault within the process as a result of this and the fault is active from

the next simulation onwards.

Note



Each action in the Fault Localisation window is logged in a log file.

Authorised persons are able view the log file.

The log file contains a list of activities which have been listed in the

Fault Localisation window. The entries contain the following data

entered by the student.

Date

Time

Faults, which have been correctly identified and eliminated are marked

in green.

5.13

Logging of eliminated

faults



This is how you access the log file

1. Open the Fault Log window by activiating Fault Log in the Extras

menu under Fault Simulation.

2. A dialog box is then displayed for you to enter the password.

Enter the password. Provided that you have not changed the

password since CIROS® Mechatronics has been installed, the

standard specified password is still valid.

Enter didactic in the Password box.

Please note that the password is case-sensitive.

Confirm your entry with OK.

3. The Fault Log window is now displayed.

To cancel the fault log, activate the context-sensitive menu via the right

mouse button and select the appropriate command.

Notes


CIROS® Mechatronics is a multimedia training aid for use in the field of

automated systems. The examples given represent practice-related

applications. The exercises are based on industrial process sequences

and aim to portray a holistic training process. With CIROS®

Mechatronics , you will be training in both methodology and

professional competency.

CIROS® Mechatronics provides process models for systems of varying

complexity from the production sector.

The general training aims to be achieved with CIROS® Mechatronics are

to be able to

Analyse and understand the mode of operation and system

structure of PLC controlled systems,

Create and test PLC programs or clearly configured systems and

Carry out systematic fault finding as part of maintenance and

corrective maintenance.

These general training aims cover all subject areas that can be taught by

means of simulated processes. The main focus of training is on a

methodical approach.

Significance of the training contents in industrial practice

One of the most important influences in industrial development over the

past few years has been the ever increasing degree of automation,

growing complexity of processes and faster operating cycles. The

keywords here are optimal utilisation of high investment, flexible and

cost effective production. More specifically these include:

High degree of machine efficiency,

Less downtimes,

Optimisation of systems,

Continual improvement processes.

6. The following training contents can be taught with CIROS® Mechatronics

6.1

Training contents



As a result of this, those who are dealing directly with a system are to

some extent faced with entirely new demands. A system operator now

takes on minor maintenance work and possibly some corrective

maintenance, as does the installer. A mechanical maintenance engineer

must have sufficient knowledge and understanding of electrical and

electronic control technology to draw the necessary conclusions

regarding pneumatics, hydraulics and mechanics. Conversely, an

electrical engineer requires knowledge about pneumatic and hydraulic

actuators. At the same time, these changing requirements lead to new

forms of collaboration.

Grouped together, these requirements can be put into three areas

Technology know-how

System know-how and system understanding

Socio-cultural skills

With CIROS® Mechatronics you will develop your knowledge and

practice your skills in the areas of technology know-how as well as

system know-how and understanding. Apart from technical know-how,

these skills also include decision-making responsibility and

methodological compentency .

The target group for CIROS® Mechatronics includes all those whose

professional area of activities involves PLC programming, maintenance

and corrective maintenance or those who need to have a basic

knowledge on these topics.

These include:

Professional teachers/instructors

‟ Mechatronics engineers

‟ Electrical engineers, for instance specialising in automation

technology

‟ Industrial mechanical engineers

Professional qualifications in metal-working and electrical

engineering

Vocational training at colleges and universities

6.2

Target group



Knowledge is required of the following in order to work and train with

CIROS® Mechatronics :

A basic knowledge of control technology: Structure of an automated

system

A basic knowledge of PLC technology: Design and mode of operation

of a PLC

A basic knowledge of PLC programming and handling of a PLC

programming tool, such as the programming system SIMATIC STEP 7

A basic knowledge of pneumatic control technology: Drives, control

elements

A basic knowledge of sensor technology: Limit switches, contactless

proximity sensors

A basic knowledge of designing, wiring and tubing of

electropneumatic systems.

A basic knowledge of electrical engineering: Electrical variables,

correlations and calculations thereof, direct and alternating current,

methods of electrical measurement

Basic knowledge of how to read and interpret circuit diagrams

The ability to deal with and operate Windows programs

Below is a list of training aims on the subjects of system know-how, PLC

programming and systematic fault finding. The training aims are taken

from the 1999 sillabus for Mechatronics engineers. The contents have

been adapted and weighted accordingly such as for instance for the

2003 syllabi for electronic engineers.

Mechatronics and electronics engineers are two examples of how

vocational training in Germany is currently updated and adapted to the

new training area concept.

The tables below list only those training aims which can also be taught

with CIROS® Mechatronics.

6.3

Previous knowledge

6.4

Example: Assigning

training aims to training

courses



Training content: Analysis of mode of operation and structure of a

system

Mechatronics engineer

Area of training Training aims

Area of training 1:

Analysis of functional interrelationships

within mechatronic systems

To read and use technical documentation.

To have a command of processes in order to be able to

analyse and document functional interrelationships.

To draw up and interpret block diagrams.

To identify the signal, material and energy flow with the

help of technical documentation.

Area of training 4:

Investigating the energy and information

flow in electrical, pneumatic and

hydraulic modules

To understand basic control technology circuits: To actuate

(pneumatically and hydraulically) a single-acting and

double-acting cylinder, basic logic operations, contactor

circuits, digital circuits.

To read and use circuit diagrams.

To identify power supply units in electrotechnology,

pneumatics and hydraulics.

To identify and describe the control functions of simple

control systems.

To design a control system (block diagram).

To identify signals & measured values in control systems.

Area of training 7:

Realisation of mechatronic subsystems

To understand and describe mechatronic subsystem

structures.

To understand and analyse the mode of operation, signal

behaviour and the use of components (sensors and

actuators).

To understand basic circuits and the mode of operation of

drives.



Mechatronics engineers (continuation)

Area of training Training aims

Area of training 8:

Design and construction of mechatronic

systems

To describe the structure and signal pattern of mechatronic

systems.

To analyse the effect of changing operating conditions on a

process cycle.

Area of training 9:

Analysing the information flow in

complex mechatronic systems

To describe the information structure (signal structure,

signal generation, signal transmission) of a system with the

help of circuit diagrams.

To establish the interrelationship between electrical,

pneumatic and hydraulic components.

To analyse signals (binary, analogue, digital) and to

deduce potential error sources.

To use computer-aided diagnostic methods, e.g. testing

and diagnostic functions of a programming system or bus

system.

Area of training 11:

Commissioning, fault finding and

corrective procedures

To analyse mechatronic systems on the basis of technical

documentation and to break down their configuration into

function blocks.


Handover of mechatronic systems to

customers

To describe mechatronic systems.

To create operating instructions and documentation.



Training content: PLC programming and testing of the program

Mechatronics engineers

Area of training Training aim

Area of training 7:


To understand the design and mode of operation of a PLC.

To design and document control systems for simple

applications.

To program simple control processes via PLC: Logic

operations, memory functions, timers, counters.

To carry out programming in one of the PLC programming

languages ‟ ladder diagram, function chart or statement

list ‟ in accordance with DIN EN 61131-3.

To document control systems in function diagrams and

function chart according to DIN EN 60848.

Area of training 8:

Design and creation of mechatronic

systems

To program mechatronic systems in one of the

programming languages ‟ ladder diagram, function chart,

statement list, sequential function chart.

To program the mode section.

To program a sequence control.

Area of training 9:

Analysing the information flow in


To use computer-aided diagnostic methods, e.g. testing

and diagnostic functions of the programming system.




To eliminate errors in the PLC program.



Training content: Systematic fault finding on systems

Mechatronics engineers

Area of training Training aim

Area of training 4:

Analysing the energy and information

flow in electrical and hydraulic modules

Fault finding on simple modules with the help of

measurement technology.

Area of training 7:


To check control systems for simple applications, e.g. by

means of signal analysis.

Area of training 8:

Design and creation of mechatronic

systems

To identify errors by means of signal analyses at interfaces

and eliminating error causes.

Computer simulation

Area of training 9:

Analysing the information flow within


To analyse signals (binary, analogue, digital) and deduce

potential error sources.

To use computer-aided diagnostic methods, e.g. the

testing and diagnostic function of the programming

system.




To understand the procedure for fault finding in electrical,

pneumatic and hydraulic systems.

To carry out a fault analysis.

To have a command of and apply systematic fault finding.

To recognise typical error causes.

To make specific use of diagnostic systems.

To document faults.

To create a log of corrective procedures.



CIROS® Mechatronics is a motivating, multimedia training aid on the

subject of automated systems.

The systems vary in complexity and can be flexibly programmed.

Problem definitions can thus be formulated according to requirements

and the instructor’s previous knowledge. It is therefore for instance

possible to analyse the mode of operation of individual components.

Similarly, it is possible to program and test the mode section of a

system.

Simulated processes have an innate didactic quality:

They are practice-related and as representational as possible.

The ability to experiment with process models creates an

environment close to that of an actual system, which is the real

object of training and knowledge is tested and consolidated.

Practice-related experience with simulated processes lends a new

dimension and quality to knowledge in that theoretical knowledge

becomes application and practice-orientated competence.

CIROS® Mechatronics supports self-motivated, experimental learning:

A simulated system operates in the same way as an actual system.

This enables students, for instance, to immediately see whether

they have programmed the sequence of a system correctly. The

effect of incorrect operation also is apparent without causing any

damage to the system. This enables students to independently

reach and analyse their findings.

Students can access technical documentation about process models

according to their needs.

Students can practice their knowledge and skills on a wide range of

different process models.

6.5

The training concept of




What are the advantages of CIROS® Mechatronics as a training medium?

CIROS® Mechatronics is a PC-assisted training aid and therefore

represents an alternative training method. Training can be devised

in a diversified and motivating way.

Industry-based process models are used to practice and consolidate

the knowledge and skills acquired on actual systems.

Simulated processes can be used to highlight and experiment with

statuses, which would be too hazardous on actual systems.

Efficient, practice-related hands-on training is possible without the

use of an actual system.

A one-off, actual system is available in the form of several simulated

systems, which increases the availability of this system for training

purposes.

The actual and virtual world of automation can be combined in any

way and adapted to the requirements of the learning process.

All systems simulated in CIROS® Mechatronics are also available in

the form of actual systems and can be ideally combined and

supplemented for training.

Skills and activities which can only be acquired and practiced on

actual systems should not to be replaced, but supplemented,

practised and consolidated.

Simulation is an advanced tool for use with automated systems.

Example 1

To ensure that the PLC programs and design of a system are ready at

the same time, appropriate simulation of the system is used to test

the PLC program.

Example 2:

Since production systems should have as few downtimes as

possible, simulated systems are often used to train and familiarise

operators and maintenance personnel with systems.


CIROS® Mechatronics supports you in many different ways with the

familiarisation and analysis of a system.

The systematic procedure you use to do so and the knowledge you

acquire can be transferred to any system and of course also an actual

system.

Load a process model to CIROS® Mechatronics . Whilst the process

model is being simulated, you can control, monitor and analyse the

process, which follows the specification of the PLC program provided.

The supplied PLC program defines a possible sequence and operation of

the process. The process model can however also be controlled via a

different PLC program.

The selected process model is operational and there are no faults in

the process.

The selected process model is to be controlled via the internal PLC.

A correct STEP 7 PLC program is available in the form of a sample

program. The sample program is downloaded to the internal PLC.

These training aims can be taught with the use of CIROS®

Mechatronics:

To analyse and understand automated systems on the basis of

technical documentation and with the help of simulated processes.

To identify the function and mode of operation of the individual

components.

To break down the system into function blocks in order to identify

the system structure.

To identify and track the signal, material and energy flow of the

system.

7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics

Prerequisite

7.1

Training aims

Main training aim

General training aims



To identify the controller behaviour and the operating sequence of

the system with the help of the technical documentation, i.e.

Function Chart.

To familiarise students with the operation of the system.

To understand the product and the processing method.

To investigate the system with the help of the simulated process.

To use the technical documentation specifically to investigate the

system.

The technical documentation is comprised of the following: Function

chart, circuit diagrams, operating instructions, commissioning

instructions, data sheets.

To identify the advantages of a simulated process for the operating

sequence.

To be able to understand and analyse a system, you will need to

subdivide.

One possible way, is to subdivide a system into the areas of system and

controller structure, mechanical configuration, drive technology, control

elements, control system, signal generators and energy supply.

No. Function scope Components and component parts

1 System structure and

controller structure

Program flow charts, function charts, function diagrams,

description

2 Mechanical configuration Support and mounting unit, function units, adjustment

3 Drive technology Electrics, hydraulics, pneumatics, mechanics

4 Control elements Electrics, hydraulics, pneumatics, mechanics

5 Control system Electrical relay controller, PLC, pneumatics, CNC, robot controllers

6 Signal generators Binary sensors, analogue sensors, digital sensors

7 Energy supply Electrics, hydraulics, pneumatics

Structure of a system

7.2

Methods



This structure serves as the basis for a systematic procedure to analyse

and investigate the system.

Questions regarding the individual function scopes provide ideas and

guidance as to what exactly you should investigate within the individual

function scopes.

Function scope - system and controller structure

‟ What is the function of the system?

‟ What is the system to produce?

‟ How is the operating sequence of the system defined?

‟ What control functions are provided?

‟ What display functions are provided?

‟ What type of control system is available: Logic control system,

sequence control?

‟ What function units does the system consist of?

‟ Are the function units or components networked?

‟ What bus systems are used: PROFIBUS, AS-i, Ethernet, or similar?

‟ What information is exchanged within the system?

‟ What information is exchanged with other systems or higher order

processes?

‟ What does the material flow look like?

‟ What does the signal flow look like?

‟ What does the energy flow look like?

‟ What does the information flow look like?

‟ What are the possibilities of tracing the signal flow?

‟ Program flow chart

‟ Function chart

‟ Function diagrams

‟ Description

‟ Operating instructions

‟ Commissioning instructions

Questions

Documents



Function scope - drive technology

‟ What drives are incorporated: Linear drive, swivel drive, rotary drive,

electric motor

‟ Which drive technology is used: Electrical, pneumatic, hydraulic?

‟ Circuit diagrams

‟ Data sheets

Function scope - control elements

‟ What control elements are incorporated?

‟ How are the control elements actuated: Electrically, pneumatically,

hydraulically?

‟ How high is the control voltage used for electrically actuated control

elements?

‟ What interfaces occur between the signal control section and the

power section?

‟ How do the control elements react in the event of Emergency-Stop?

‟ What are the status display options of control elements?

‟ Circuit diagrams·

‟ Data sheets

Function scope - the control sysem

‟ How is the control system realised: PLC, relay control, robot control,

CNC, pneumatic control?

‟ Which control energy does the PLC require?

‟ What is the voltage applied at the PLC inputs?

‟ What is the voltage applied to the PLC outputs?

‟ Is a bus system used?

‟ Which fieldbus system forms part of the control system?


‟ Data sheets

Questions

Documents

Questions

Documents

Questions

Documents



Function scope - signal generators

‟ Which signal generators are incorporated: Binary, analogue, digital?

‟ Which electronic signal generators are incorporated: Optical

sensors, inductive sensors, capacitive sensors, magnetic sensors?

‟ What is the design (polarity of the output signal) of the electronic

sensors: PNP, NPN?

‟ Which mechanically actuated sensors are incorporated?

‟ Which pressure sensors are incorporated?

‟ What are the status display options of the sensors?


‟ Data sheets

Function scope - energy supply

‟ Which energy supply is used?

‟ How high is the operating pressure in the case of pneumatic or

hydraulic energy supply?

‟ Is direct or alternating current used?

‟ How high is the operating voltage: 24 V or 230 V?


‟ Data sheets

Questions

Documents

Questions

Documents



CIROS® Mechatronics supports you with the following during your

analysis and investigation of the system:

Simulation of the process model and execution of the PLC program

in the internal PLC.

Window for PLC inputs/outputs: Display of the PLC inputs/outputs.

Window for manual operation: To monitor process activities and

process statuses.

Window for manual operation: To set breakpoints to enable you to

monitor system operation step by step.

Window for manual operation: To set specific breakpoints in order to

stop the process at a particular step.

CIROS® Mechatronics Assistant: Provides information on-line, such

as circuit diagrams for the process model.

Investigating the operating sequence of the Distributing station

Investigate the operating sequence of the Distributing station. To do so,

use the checklist containing the system structure.

Answer the following questions:

How is the initial position of the system defined?

What is the purpose of the Reset function?

What is defined as the start precondition: Does it include the

execution of the Reset function?

How does the Distributing station react if no more workpieces are

available?

No more workpieces are available in the stacking magazine. What

do you need to do for the station to operate correctly again?

7.3

Support via


7.4

Example

Exercise



1. Load the Distributing process model. Make sure that the process

model is controlled via the intenal PLC using the sample PLC

program. This applies in the case of the reference models.

2. The system can be broken down into the following function blocks:

Stacking magazine, swivel drive and electrical. The electrics also

include the PLC.

Implementation



3. Refer to the technical documentation for information regarding the

initial position and start condition of the system.

To do so, access the on-line help for the process model. Click onto

Help on Work cell in the Help menu.

The required information is available in the chapters „The

Distributing Station“ and „Technical Documentation“.



Initial position: Ejecting cylinder extended (1B2=1) and swivel arm at

magazine (3B1=1) and workpiece not picked up (2B1=0).

The system moves to the initial position via the Reset function.

The start condition is met if the station is reset and in the initial

position.

4. Start the simulation of the process model by clicking onto Start in

the Simulation menu.

5. Control the process by means of the pushbuttons and switches of

the control console.

Carry out the reset function first by clicking onto the green

illuminated Reset button.

Then place two workpieces into the magazine by selecting the

desired workpiece on the workpiece table via a mouse click. Now

click onto the appropriate symbolic workpiece on the Distributing

station.

Start executing the process by clicking onto the Start button.

You can now follow the implementation of the process.

Result



6. If there are no further workpieces in the magazine, the swivel arm

stops in the adjacent station position. The indicator light Q1 is

illuminated. The designation of the indicator light in the circuit

diagram is P3.

7. Fill the magazine with workpieces. Click onto the illuminated Start

button to acknowledge that you have finished filling the magazine.



8. Open the Manual Operation window, if you want to execute a

process sequence step by step, to enable you to monitor it more

effectively. To do so, click onto Manual Operation in the Modeling

menu.

Highlight all the process activities and set breakpoints at these

process activities by activating the context sensitive menu via the

right mouse button. Select Stop at Value Change.

Start the simulation of the process model. Simulation stops at each

value change. As soon as simulation is re-started, the next step is

executed.



9. You can trace the signals in the process via the status display in the

Manual Operation window or via the LEDs of the process

components.

10. To access information regarding the circuit diagram designations of

process components, click onto the LED or the air connection of a

component.

If, as a result of simulation, the process model reaches a status you

cannot or do not want to work with any longer, return the process model

to the initial position by stopping the simulation. Then click onto Reset

Workcell in the Simulation menu.

Determining the components of the Distributing station

Investigate the design of the Distributing station. Use the checklist

detailing the structure of the station and the questions regarding the

system for this.


With which valve is the swivel drive actuated?

How is the vacuum generated?

What are the designations of the solenoid coils of the valve for the

ejection of the workpieces?

Via which sensor is the filling level of the magazine monitored?

How many PLC inputs and PLC outputs are required for the control of

the Distributing station?

Note

7.5

Example

Exercise




model is controlled via the internal PLC using the sample PLC

program. This applies in the case of the reference models.

Implementation




process components and their circuit diagram designations.

To do so, open the on-line help for the process model and click onto

Help on Workcell in the Help menu.

The required information is available in the chapter „Technical

Documentation“.



The swivel drive is actuated via two 3/2-way solenoid valves. This valve

combination has the function of a 5/3-way solenoid valve with mid-

position pressurised. The circuit diagram designation for this valve is

3V1.

The vacuum is generated via a 2/2-way solenoid valve. The second

2/2-way solenoid valve creates an ejector pulse, which results in

reliable ejection once the vacuum is switched off. The circuit diagram

designation for the valve is 2V1.

All valves are housed on one valve terminal.

The designation of the valve coil of valve 1V1 for the actuation of the

ejecting cylinder is 1M1.

The filling level of the magazine is checked via the optical sensor with

the circuit diagram designation B4.

3. Take a look also at the process components in the process model

itself.

Click onto the LED or the air connection in order to display the

designation.

To enlarge or turn the components, use the options in the View

menu.

You can restore the standard setting of the process model by

clicking onto Standard Views in the View menu and then selecting

Default Setting.

Result



4. Determine the number of PLC inputs and outputs required to control

the process.

You will find the relevant information for this in the technical

documentation via the on-line help.

You can however also display the PLC inputs/outputs and their

statuses in a separate window for the process model by clicking

onto Inputs/Outputs under View and selecting Show Inputs and

Show Outputs.

The process control system requires 12 PLC inputs and 8 PLC outputs.

The additionally displayed inputs/outputs can be used to expand the

control system.

Result



Tracing the signal and energy flow on the Distributing process model

Investigate the signal and energy flow of the Distributing station.

To do so, trace the signal of the sensor 1B1 up to the respective PLC

input.

Trace the signal and energy flow from the PLC output 3M1 to the

pneumatic drive.

Answer the following additional questions:

To which PLC input is the sensor 2B2 connected?

To which PLC input is the sensor B4 connected?

Which drive is actuated via the solenoid coil 1M1?

To which PLC output is the vacuum generator connected?


model is controlled via the internal PLC using the same PLC program.

This applies in the case of the reference models.

7.6

Example

Exercise

Implementation




signal and energy flow of the sensor 1B1 and the PLC output 3M1.



The required information is available in the chapter „Technical

Documentation“.

The sensor 1B1 is connected to the PLC input 1B1 (I0.2).

The PLC output 3M1 (O 0.3) controls the valve coil 3M1 of the valve 3V1.

3. Move the process model into the initial position by clicking onto

Reset Workcell in the Simulation menu.

4. Start the simulation by clicking onto Start in the Simulation menu.

5. Establish where the components are located in the system and

investigate the signals and energy flow of these. You will recognise

the components by their circuit diagram designation.

6. Control the process by using the pushbuttons and switches of the

control console.

First, carry out the reset function by clicking onto the green

illuminated Reset button.

Then fill the magazine with workpieces by clicking onto the

workpiece on the station.

Start the process operation by clicking onto the Start button.

You can now follow the process execution.

Result



7. Carry out the process activity step-by-step to enable you to better

monitor everything. Open the Manual Operation window by clicking

onto Manual Operation in the Modeling menu.

Highlight all the process activities and set the breakpoints at these

by activating the context sensitive menu via the right mouse button.

Select Stop at Value Change.

Start the simulation of the process model. Simulation stops with

each value change. The next step in the process is executed as soon

as you restart simulation.



8. Monitor the signal flow of the sensor 1B1.

The sensor 1B1 is connected to the PLC input 1B1, i.e. to

STATION_1B1. The sensor status can be established via the LED on

the sensor. You can also monitor the switching status of the sensor

in the Manual Operation window.

If the sensor 1B1 switches, then a 1-signal is applied at the PLC

input STATION_1B1. The status of the PLC inputs is displayed in the

Inputs window. Open this window by clicking onto Inputs/Outputs

in the View menu and select Show Inputs.



9. Monitor the signal and energy flow of the PLC output STATION_3M1.

The PLC output STATION_3M1 is connected to the valve coil 3M1.

The status of the PLC can be established in the Ouputs window.

Open this window by clicking onto Inputs/Outputs in the View menu

and select Show Outputs.

If a 1-signal is applied at the PLC input, voltage is also applied at the

valve coil 3M1. The LED of the valve coil is illuminated. If a 0-signal

is also applied simultaneously at the valve coil 3M2, then the

valve 3V1 switches. The swivel arm moves into the magazine

position.


When investigating a system, the main focus can be put on

familiarisation with the components, in which case the system will not

be not controlled via a PLC program.

To enable you to more closely observe the mode of operation and

behaviour of a component, CIROS® Mechatronics allows you to operate

individual actuators “by hand”, similar to an actual station. With manual

operation, an electrical signal is generated at the selected solenoid coil

and the valve switches according to the signal applied and controls the

drive.

The system components can be specifically controlled via manual

operation. You can trace the signal and energy flow, identify interfaces

and therefore systematically analyse and understand the system.

The process model selected is operational and there are no faults

within the process.

The process model selected will not be controlled via a PLC. The

working energies current and compressed air are connected.

The following training aims can be taught with the use of CIROS®

Mechatronics:

Familiarisation with the individual components of an automated

system: Mode of operation, status display elements, mechanical

characteristics.

8. This is how you establish the mode of operation of the components forming part of a system in CIROS® Mechatronics

Prerequisite

8.1

Training aims

Main training aim



Familiarisation with the mode of operation of sensors and limit

switches.

To be able to identify application areas for optical, magnetic,

inductive and capacitive sensors.

To be familiar with the DC motor as an example of an electrical drive.

To know of examples for pneumatic linear drives and rotary drives.

To be familiar with the design and mode of operation of

electropneumatic valves.

To analyse and understand the signal and energy flow of

components.

To be familiar with electropneumatic circuits.

To be familiar with status display components on electrical

components and to use these for signal tracing.

Use a systematic approach to familiarise yourself with a system or

system components. The instructions for a systematic procedure are set

out in Chapter 7.

CIROS® Mechatronics supports you with the following during your

analysis and investigation of the components which formpart of a

system:

Simulation of the process model. The PLC programs are not active

during this.

Window for manual operation: Monitoring of process activities and

statuses.

Window for manual operation: Initiating individual process

activities.

CIROS® Mechatronics Assistant: Provides information on-line, such

as circuit diagrams for the process model.


8.2

Methods

8.3

Support via




Investigating the mode of operation of the ejecting cylinder in the

stacking magazine module

Investigate the mode of operation of the stacking magazine.


How is the initial position of the stacking magazine defined?

What is the status of the ejecting cylinder in the initial position?

How do you identify whether the ejecting cylinder is extended or

retracted?

Via which valve is the ejecting cylinder actuated?

What is the designation of the valve solenoid coil for the actuation of

the ejecting cylinder?

How can you identify whether voltage is applied at the solenoid coil?

Is the sensor for workpiece detection an inductive, capacitive or

optical sensor?

Which signal is applied at the sensor if a workpiece is available in

the magazine?

8.4

Example

Exercise



1. Load the stacking magazine process model. No sample PLC program

is available for the stacking magazine.

Proceed as follows, when carrying the investigation of individual

components on a process model for which a sample program is

available:

Load the process model controlled via the internal PLC.

Open the Manual Operation window.

Activate the context-sensitive menu via the right mouse button.

Select Disconnect all Controllers.

Carry out your investigations by means of manual operation.

Once you have completed your investigations and want to control

the process model via the internal PLC, connect the simulation of the

process model with the internal PLC. To do so, activate the context-

sensitive menu via the right mouse button and select Restore I/O

Connections.

Implementation

Note



2. Establish which components the stacking magazine consists of.

You can find the relevant information by clicking onto the LED or the

compressed air connection of the component. Additional

information is available in the technical documentation. This

technical documentation is available on-line. To access this, open

the on-line help for the process model by clicking onto Help on Work

cell in the Help menu.

You will find the required information in the chapter „Technical

Documentation“.



The ejecting cylinder separates out the workpieces.

The end positions of the ejecting cylinder are detected via two sensors:

Sensor 1B1 (ejecting cylinder retracted), sensor 1B2 (ejecting cylinder

extended).

The valve for the actuation of the ejecting cylinder is a 5/2-way solenoid

valve with the designation 1V1.

The valve coil 1M1 actuates the valve 1V1.

The optical sensor B4 detects whether a workpiece is available in the

magazine.

3. Make sure that the stacking magazine is in the initial position by

clicking onto Reset Workcell in the Simulation menu.

In the initial position, the ejecting cylinder is extended.

4. Start the process model simulation by clicking onto Start in the

Simulation menu.

Result



5. Open the Manual Operation window by clicking onto Manual


6. Add a workpiece into the magazine by clicking onto one of the

workpieces on the slotted assembly board.

Check whether the status of the sensor B4 changes.

You can identify the switching status of the sensor on the LED of the

sensor. You can however also establish the sensor status via the

Manual Operation window.

No workpiece available: B4=1

Workpiece available: B4=0.

Result



7. Eject a workpiece from the magazine by applying a 1-signal at valve

coil 1M1.

Double click onto line 1 of the process activities. Valve coil 1M1 is

set at value 1 and the ejecting cylinder ejects a workpiece. No

compressed air tubing is shown in the simulation. Applied

compressed air is signalled by means of a blue connection.



8. Return the magazine ejector to the magazine by double clicking onto

line1 of the process activities. This double click changes the value of

the valve coil from 1 to 0; the ejecting cylinder extends again.

9. Remove the ejected workpiece by double clicking onto line 2 of the

process activities. The workpiece is removed.


CIROS® Mechatronics offers you numerous process models for

automated applications that are typical in industry. You determine the

process sequence, which can be either simple or complex. You then

create the PLC program for this sequence in the programming system

and for the PLC of your choice. The PLC program is subsequently used to

control the process model. You can immediately detect whether the PLC

program is operating correctly. If errors occur, then use the testing and

diagnostic functions of your programming system for error detection

and error elimination.

The main focus of CIROS® Mechatronics as part of PLC programming is

on:

Practising a systematic procedure to create the PLC program.

Systematic testing of the PLC program on the simulated process.

The advantage is that relevant actual systems exist for these process

models. This enables you to carry out comprehensive commissioning on

the actual systems with the tested PLC programs.

The selected process model is operational and there are no faults

within the process.

The process model selected is to be controlled via an external PLC.

CIROS® Mechatronics is a tool for the process of creating a PLC

program. With the help of this tool you can teach the following training

contents.

To design, create and test PLC programs for simple motion

sequences.

9. This is how you use CIROS® Mechatronics in PLC programming

Prerequisite

9.1

Training aims

Main training aim for the

Beginners target group

Beginners



To describe the design and function of a PLC.

To list the differences between a PLC and relay control.

To realise simple control tasks using basic logic functions (and

timers).

To program simple control tasks in one of the programming

languages: Ladder diagram, function chart or statement list

according to DIN EN 61131-3.

To test PLC programs for simple control tasks.

To systematically solve simple control problems from problem

definition and analysis through to finding a solution, programming,

checking and documentation.

To design, create and test a PLC program for extensive control

systems.

To program sequence control systems in sequential function chart

according to DIN EN 61131-3.

To program the mode section.

To utilise the diagnostic and testing functions of the PLC

programming system.

To systematically solve control tasks from problem definition and

analysis through to finding a solution, programming, checking and

documentation.

PLC programs ‟ or more generally control programs - are an important

component part of an automated system. In order for PLC programs to

be as error-free, easy to maintain and cost effective as possible, they

need to be systematically designed, well structured and documented in

detail.

Proceeding in stages has proved a successful method for the

development of a PLC program. Breaking down the process into stages

or sections provides a targeted, systematic approach and gives clearly

configured results that can be checked against the problem definition.

General training aims for

the target group Beginners

Main training aim for the

Advanced target group

General training aim for

the Advanced target group

9.2

Methods



Stages Activities Result/documents

Specification

(description of the

control task)

‟ Description of the system

‟ Defining the system process

‟ Function description

‟ Positional sketch

‟ Technology layout

Planning and design

(description of the

solution)

‟ Planning the system

‟ Defining the control technology

requirements (Emergency-Stop, modes

of operation, visualisation...)

‟ Design of the PLC program (formal

representation of the sequence and

logic of the PLC program)

‟ Circuit diagrams·

‟ Parts lists·

‟ Solution in the form of a function

table or logic diagram to IEC 617-12

for sequence controllers

‟ Solution in the form of a function

chart to DIN EN 60848 for sequence

controllers

‟ Function diagrams

‟ Definition of software modules

Realisation

(implementation of

the solution)

‟ Programming of the PLC program

‟ Simulation and testing of program

sections and the overall program

‟ Construction of the system

‟ Annotated PLC program in one of

the programming languages to DIN

EN 61131-3

Commissioning

(integration and

testing of the

solution)

‟ Testing and commissioning of the

control system

‟ Operational PLC program

‟ Commissioning report

‟ Storage medium with PLC program

‟ Full documentation

Stages within the systematic solution of a control task

CIROS® Mechatronics with the following for PLC programming:

Industry-typical, realistic process models of varying complexity.

Simulation of the process model.

Control of the process model via OPC interface using any PLC (for

example via S7-PLCSIM).

Window for PLC inputs/outputs: Display of PLC inputs/outputs.

Window for manual operation: Monitoring process activities and

process statuses.

9.3

Support via




CIROS® Mechatronics Assistant: Provides information such as

system description or circuit diagrams.

Programming the display of the initial position of the Distributing

process model.

On the Distributing station, the indicator light H1 is to be illuminated if

the station is in the initial position.

The technical documentation for the station is to be used, such as the

circuit diagrams and symbols table. You will find these in CIROS®


Represent the control function in the form of a logic diagram.

Program the control task in one of the following languages: Ladder

diagram, function chart or statement list.

Test the PLC program using the simulated process model.

9.4

Example

Exercise

Ancillary conditions

Your task



Implementation using the programming system STEP 7and the Soft

PLC S7-PLCSIM


2. Load the Distributing process model. The process model is to be

controlled via an external PLC. The prerequisite for this is that

OPC Server is displayed in the Type column of the Switch external

PLC <-> internal PLC window. Should this not be the case, then

double click onto this line.



3. Use the technical documentation to find out how the initial position

of the station is defined.



You will find the required information in the chapters „The


Initial position: Ejecting cylinder extended (1B2=1) and swivel arm at

magazine (3B1=1) workpiece not picked up (2B1=0).

4. Formulate the control function in the form of a logic diagram.

1B1 P1

3B1

2B1

&

Logic diagram

5. Create the symbols table for the control function.

Take the required inputs/outputs from the general symbols table for

the Distributing station. The symbols table is available via the on-

line Help for the work cell. Activate the on-line Help by clicking onto

Help with the Work Cell in the Help menu.

Symbol Address Data

type

Comment

1B2 I 0.1 BOOL Ejecting cylinder extended

2B1 I 0.3 BOOL Workpiece picked up

3B1 I 0.4 BOOL Swivel arm in magazine position

P1 O 1.0 BOOL Indicator light Initial position

Result

Result

Result



6. Start STEP 7 or the SIMATIC Manager.

7. Plan a project for the control function.

8. Create the PLC program and store this.

9. Open S7-PLCSIM by clicking onto Simulate Module under Options in

the SIMATIC Manager.





11. Load the PLC program to the S7-PLCSIM. In order to do this,

highlight the folder Module, then click onto Load in the Target

System menu.

12. Start the S7-PLCSIM by clicking onto the box next to RUN in the CPU

300/400 window.

13. Start the process model simulation by activating Start in the

Execute menu.

With the starting of the process model simulation, the communication

program EzOPC is also started. If EzOPC is started, both communication

users - S7-PLCSIM and process model simulation must already be

active. Only then can the communication link be correctly set up.

Note



14. Carry out the settings in EzOPC.

Click onto the EzOPC button in the Start bar. This will open the

EzOPC window.

The current communication links are displayed in the Overview

register. You can change the communication link by clicking onto the

appropriate button. The following communication links must be

available for your task: Process simulation in CIROS must be

connected to the S7-PLCSIM controller via the virtual controller.



15. Now check the settings for the virtual controller by clicking onto the

Vitual Controller register. 8 input bytes and 8 output bytes are

preset for data exchange. You can accept this setting unaltered. The

first two bytes are required at any one time.



16. Now check the settings for S7-PLCSIM by clicking onto the

S7-PLCSIM register. 8 input bytes and 8 output bytes are also

preset in this case and you can accept these settings unaltered also.

The first two bytes are required at any one time.


18. If your PLC program is correct, the indicator light P1 is illuminated if

the station is in the initial position.



19. If PLC program still contains errors, then the on-line view in STEP 7

will support you ideally during fault finding. Call up the program

module, in which you suspect the fault and activate Monitor in the

Test menu. You can now monitor in parallel with simulation, which

PLC program sections are or are not being executed.



Programming a simple sequence for the Distributing station

A simple sequence is to be programmed for the Distributing station.

The sequence is defined as follows:

1. The swivel drive swivels to the „Succeeding Station“ position, if

workpieces are detected in the magazine and the Start button is

pressed.

2. The ejecting cylinder retracts and ejects a workpiece from the

magazine.

3. The swivel drive moves to the „Magazine“ position.

4. The vacuum is switched on. If the workpiece is reliably picked up, a

vacuum switch switches.

5. The ejecting cylinder extends and releases a workpiece.

6. The swivel drive moves to the „Succeeding Station“ position.

7. The vacuum is switched off.

8. The swivel arm moves to the „Magazine“ position.

The technical documentation for the station is to be used, such as

circuit diagrams and the symbols table. You will find these in CIROS®


Represent the control task in function chart according to

DIN EN 60848.

Program the control task in sequential function chart.

Test the PLC program with the simulated process model.

9.5

Example

Exercise

Ancillary conditions

Your task



Implementation using the programming system STEP 7 and the Soft

PLC S7-PLCSIM


2. Load the Distributing process model. The process model is to be

controlled via an external PLC. The prerequisite for this is that

OPC Server is displayed in the Type column of the Switch external

PLC <-> internal PLC window. If this is not the case, then double click

onto this line.



3. Refer to the technical documentation to find out which process

components are used and what the designations of the components

are in the circuit diagram.

Open the on-line help to do so and activate Help on Workcell in the

Help menu.

You will find the required information in the chapter „Technical

Documentation“.

4. Formulate the control task in function chart.



Station in initial position andpart in magazine and Start button

Function chart to DIN EN 60848 (IEC 60848)

1Start

2Swivel arm

to“SucceedingStation” pos.

Swivel arm to“Succeeding Station” position

Swivel arm in “Succeeding Station” position

Swivel arm in “Succeeding Station” position

Workpiece not picked up

4Swivel arm

to“Magazine”

position

8Swivel arm

to“Magazine”

position

6Swivel arm

to“SucceedingStation” pos.

5Pick up

workpiece

7Deposit

workpiece

3Eject

workpiece

Magazine slide forward(ejecting cylinder to retract)

Magazine slide back(ejecting cylinder to extend)

Vacuum OFF

Swivel arm to“Magazine” position

Swivel arm to“Magazine” position

Swivel arm to“Succeeding Station” position

Vacuum ON

Workpiece ejected

Swivel arm in “Magazine” position

Swivel arm in “Magazine” position

Workpiece picked up andmagazine slide back

Function chart for the control task

Result



5. Create the symbols table for the control task.

Take the required inputs/outputs from the general symbols table for

the Distributing station. You will find the symbols table on the on-

line help for the work cell.

Symbol Address Data

type

Comment

1B2 I 0.1 BOOL Ejecting cylinder extended

1B1 I 0.2 BOOL Ejecting cylinder retracted

2B1 I 0.3 BOOL Workpiece picked up

3B1 I 0.4 BOOL Swivel drive in magazine

position

3B2 I 0.5 BOOL Swivel drive in succeeding

station position

B4 I 0.6 BOOL Magazine empty

S1 I 1.0 BOOL Start button

1M1 O 0.0 BOOL Ejecting cylinder to retract

(magazine slide advanced)

2M1 O 0.1 BOOL Switch on vacuum

2M2 O 0.2 BOOL Switch off vacuum

3M1 O 0.3 BOOL Swivel cylinder to magazine

position

3M2 O 0.4 BOOL Swivel cylinder to

succeeding station position

Result



6. Start STEP 7, i.e. the SIMATIC Manager respectively.

7. Create a project for the control task.

8. Create the PLC program and store it.

9. Open S7-PLCSIM by clicking onto Simulate Modules under Options

in the SIMATIC MANAGER.





11. Load the PLC program to S7-PLCSIM. To do so, mark the Modules

folder and then activate Load in the Target System menu.

12. Start S7-PLCSIM by clicking onto the box next to RUN in the

CPU 300/400 window.

13. Start the simulation of the process model by clicking onto Start in

the Simulation menu.

With the starting of the process model simulation, the communication

program EzOPC is also started. If EzOPC is started, both communication

users - S7-PLCSIM and the simulation of the process model ‟ must

already be active. Only then will the communication links be correctly

set up.

Note



14. Carry out the settings in EzOPC.

Click onto the EzOPC button in the Start bar to open the EzOPC

window.

The communication links are displayed in the Overview register. You

can change the communication link by clicking onto the appropriate

button. The following communication links must be available for

your task: process simulation in CIROS must be connected to the

S7-PLCSIM controller via the virtual controller.



15. Now check the settings for the virtual controller by clicking onto the

Virtual Controller register. 8 input bytes and 8 out bytes are preset

for data exchange. You can accept this setting without alteration.

The first two bytes are required at any one time.



16. Now check the settings for S7-PLCSIM by clicking onto the

S7-PLCSIM register. 8 input bytes and 8 output bytes are also

preset for data exchange in this case. You can accept these settings

unaltered. The first two bytes are required in any one case.


18. If your program is correct, you can start the sequence once you have

inserted a workpiece by clicking onto the Start button.



19. If the PLC program still contains errors, the on-line view in STEP 7

will support you ideally with fault finding. Call up the program

module, where you suspect an error. Activate the command Monitor

the Test menu. You can now monitor, in parallel with the process

simulation, which PLC programs are or are not being executed.


CIROS® Mechatronics supports you in numerous ways during

systematic fault finding on a simulated system.

The systematic procedure, the working aids and diagnostic systems

used for this and the know-how you acquire, can be applied to any

system.

Load a process model in CIROS® Mechatronics . A fault has been

previously set on this process model. You can now control and monitor

the process model as it is being simulated. Analyse the fault behaviour

and determine the cause of the fault. When you have found the cause,

eliminate the fault by entering the cause of the fault in the window

provided. If you have identified the cause of the fault, then the process

model will operate correctly during the next simulation run.

The selected process model is loaded and a fault set in the process

model by an authorised person.

The fault simulation mode is active.

The selected process model is controlled via the internal PLC. A

correct PLC program is available for this in the form of a sample

program. The sample program is automatically downloaded to the

internal PLC by opening the reference model.

You can impart these training aims with the use of CIROS®

Mechatronics :

Systematically repairing a system after a fault has occurred.

To familiarise students with and apply a general procedure for

systematic repair work in the event of a fault.

To acquire information regarding the mode of operation of a system

and system components from technical documentation.

10. This is how you carry out systematic fault finding on a simulated system

Prerequisite

10.1

Training aims

Main training aim




To determine the actual status of a system after a fault has

occurred.

To carry out systematic fault finding on PLC controlled

electropneumatic systems.

To become familiarised with and apply a strategy for fault finding on

PLC controlled electropneumatic systems.

To carry out a fault analysis.

To know the typical causes of faults.

To document faults.

To make targeted use of diagnostic systems.

To familiarise students with the working aids for fault finding.

The basic prerequisite for systematic fault finding and corrective

procedures is to understand the system. Only if you understand the

system, its structure and function can you carry out corrective

procedures.

Eliminating faults by means of systematic corrective procedures.

The following methods have proved successful with systematic fault

finding and corrective procedures:

Familiarisation with the system

Systematic repair work after a fault has occurred

Systematic determination of the actual status of the system

Systematic fault finding in general

Systematic fault finding for PLC controlled systems

Familiarise yourself with the system by:

Investigating the system.

Analysing the system documentation.

Understanding the product and the processing technology.

Conducting informative discussions with system operators.

10.2

Methods

Method: Familiarisation

with the system



In the event of an inadvertent interruption of the process, corrective

procedures are to be carried out according to the following schematic

representation:

REQUIREDstatus

ACTUALstatus

Faultdiagnosis

Faultfinding

Faultlocated

YesNo

Correctiveprocedures

Recom-missioning

Productionsystem

Com-parison

Systematic corrective procedures

In the event of a fault signal, the actual status of the system is to be

established first.

Once the actual status has been determined and compared with the

required status, the actual fault finding starts. The source of a fault is

often found during this comparison if the fault

is visible (e.g. mechanical damage on a signal generator)

is audible (e.g. leakage on a valve)

is detectable by suspicious odours (e.g. scorching of a cable).

Method: Systematic

corrective procedures after

a fault has occurred



If this is not the case, the fault can be found and eliminated by means of

systematic fault finding.

Once a fault is found, it is not enough to merely correct it. It is also

necessary to establish the cause of the fault. A list of faults is is helpful

for this and this should be stored in the system. This list describes all

the faults and their causes.

With the help of a fault list, it is possible to determine whether damage

or faults occur regularly. In this way, it is possible to identify weak areas

in the system. Once these are established, it is advisable to technically

improve the system.



First, the actual system status must be determined in the event of an

error message. Several options are available for this:

Establishing the actual status

Step 1 Determining the fault

behaviour of the system

‟ No start

‟ Standstill during process step

‟ Faulty process sequence

‟ Work result wrong

Step 2 Establishing the actual status

of the system

‟ Status displays (LED) on the system components:

‟ Current mode of operation

‟ Ready status

‟ Signal status of signal generators

‟ Switching status of control elements

‟ Switching status of PLC input/outputs

‟ Visible damage

‟ Audible damage

‟ Damage detectable by odour/smell

‟ Screen:

‟ Error message, diagnostic message

‟ Status information

‟ Machine status display

Method: Systematically

determining the actual

system status



The basis for systematic fault finding is again the desired/actual value

comparison.

Investigating possiblesources of faults by meansof testing or measurementprotocols

Determining ofACTUAL status

Comparison withREQUIRED status

Elimination of faultand recommissioning

Result

YES(fault found)

NO(fault not found)

Establishing possibleerror sourcesa

‟ Mechanical faults‟ Pneumatic faults‟ Hydraulic faults‟ Electrical faults

Overview of systematic fault finding

Method: Systematic fault

finding in general



Every controller functions on the principle of signal input, signal

processing and signal output.

Systematic fault finding for PLC controlled systems is based on this

structure.

A desired/actual value comparison enables you to narrow down the

area of the fault within the process sequence. Investigate possible

causes of faults by checking the components in the direction of the

signal and energy flow, starting from the fault location.

Method: Systematic fault

finding for PLC controlled

systems



Structure Working aids Possible error sources

Fault has occurred in the system

Establishing the actual status

Comparison of actual status with

desired status

Checking the electrical energy

supply

Voltage tester ‟ Voltage supply switched off

‟ Voltage supply to high or too low

Checking of sensor Voltage tester

LED

‟ Sensor incorrectly adjusted

‟ Sensor mechanically displaced

‟ Sensor faulty

Monitoring of PLC input LED ‟ PLC input module faulty

‟ Cable break between sensor and PLC

input

Checking of PLC LED

Programming and

testing unit

‟ PLC faulty

‟ No voltage applied

Checking of PLC output LED ‟ PLC output module faulty

Checking of control elements Voltage tester

LED

Manual override

‟ Control element mechanically faulty

‟ Control element electrically faulty

‟ Cable break between PLC output and

control element

Checking of drive Visual inspection ‟ Connections mixed up

‟ Loss of electrical connection

Checking of pneumatic or

hydraulic energy supply

Pressure gauge ‟ Energy supply not switched on

‟ Leakage in network

Systematic fault finding of PLC controlled systems



CIROS® Mechatronics supports you with the following during the

monitoring and analysis of the actual system status:

Simulation of the process model and execution of the PLC program

via internal PLC.

Window for PLC inputs/outputs: Display of PLC input/outputs.

Window for manual operation: Display of process activities and

process statuses.

Window for fault localisation: Input and elimination the cause of the

fault.

CIROS® Assistant: Provides information on-line regarding the

process model, such as circuit diagram or function chart.

Finding and eliminating faults in the Distributing station

A fault has occurred in the course of the sequence of the Distributing

station. Eliminate the fault by means of systematic corrective

procedures.

10.3

This is how CIROS®

Mechatronics supports

you

10.4

Example

Exercise



1. Load the Distributing process model with the set fault. The process

model is controlled via the internal PLC.

2. Ensure that the Fault Simulation mode is active.

3. Put the process model into the initial position by clicking onto Reset

Workcellin the Simulation menu.

4. Now start the simulation of the process model. To do so, click onto

Start in the Simulation menu.

5. Operate the process using the pushbuttons and switches of the

control console.

Implementation



6. A fault has occurred during execution, which stops the process.



7. Refer to the technical documentation to establish the correct

process execution. Open the on-line help for the process model by

clicking onto Help on Workcell in the Help menu.

You will find the required information in the chapters „The




8. Determine the actual status of the process and compare it with the

required status, thereby narrowing down the area of the fault

location within the process.

The fault is a stoppage during the process sequence. The process step

„Move swivel arm to magazine position“ is not executed. Possible

causes of the fault are: The swivel cylinder and its valve actuation or

possibly also the sensors, which should trigger the movement of the

swivel cylinder.

9. We recommend that you check the energy flow, starting from the

sensors through to the swivel cylinder. It is of course possible to

proceed in reverse and to check the signal and energy flow from the

swivel cylinder to the valve via the PLC to the sensor.

10. Find out which sensor signals need to be applied in order for the

swivel arm to move to the magazine position. Use the function chart

and allocation list from the on-line help for the Distributing work

cell.

If the reed switch 1B1 and the end position switch 3B2 are actuated, the

swivel arm should move to the magazine position.

Result

Result



11. Check the switching status of the reed switch 1B1 and the end

position switch 3B2.

Two options are possible.

Evaluate the LED in the process model. The designation of the

respective component is displayed as soon as you click onto the

LED.

Or check the signal status of the sensors in the Manual Operation

window by clicking onto Manual Operation in the Modeling window.

The LED of the reed switch 1B1 is illuminated and the sensor therefore

switches.

Result



12. Check the PLC input 1B1 connected to the sensor by opening the

PLC Inputs window. To do so, open the PLC inputs window if this is

not displayed.

Click onto Inputs/Outputs in the View menu and select Show

Inputs.

The Inputs window is displayed.

A 0-signal is applied at the PLC input STATION_1B1, even though the

sensor 1B1 switches.

You therefore suspect that the cause of the fault is a cable break at the

PLC input 1B1.

Result



13. Open the Fault Localisation window to eliminate the fault.

Click onto Fault Localisation under Fault Simulation in the Extras

menu to do so.

Then double click onto No fault on the line PLC input 1B2.

Select Cable Break in the list of options.

The simulation of the process model is continued correctly. The cause of

the fault has been correctly identified and eliminated.

Result

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