Exercises With Solution

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2012-07-31 Schuettler | Overview practical exercises Bosch Rexroth AG 1/2

Overview practical exercises

1. Emergency stop – Equipments and function

2.

Calculation of the cylinder forces – Working with the documentation

3.

Tank filling device – basics about the Software Rexroth IndraLogic

4. Local Area Network – Installation of the communication network

5.

Sequence of the magazine station – Project administrationand PLC programming

6.

Project exercise - Basic principles of PLC programming with L20 in the begin-ner's application for the electrical conveyor belt in Station 2



2/2 Bosch Rexroth AG Overview practical exercises | 2012-07-31 Schuettler



2012-07-31 Schuettler | Exercise 1 - Emergency stop Bosch Rexroth AG 1/6

Emergency stop – Equipments and function

Information

The emergency stop is operating at each single stations and also if the magazine,pneumatic press processing and storage station joint together. We will do someanalysis to get more overview and a better understanding of the equipments used inthe emergency stop and their function.

Fig: 01 Emergency stop relay and the couple relay

The following items about the emergency stop relay are necessary for a better under-standing:- Structure and operation- Shut off- Supplied equipments by the emergency stop relay

You can find this information on the documentation-CD of the mMS. Search in thetechnical data sheets and also in the electric diagram for the function of the operationof the emergency stop.

We need the details in the following summary:

a.

Internal function of the emergency stop relay.

b.

Emergency stop relay shut off of the magazine station

c. Equipment supplied by the emergency stop relay of the magazine station

d. Emergency stop relay shut off and activation of the mMS



2/6 Bosch Rexroth AG Exercise 1 - Emergency stop | 2012-07-31 Schuettler

Planning

Please find the emergency stop relay in the electrical diagram.Do you understand all the used symbols?What is the equipment marking of the emergency stop relays?Please overview the technical data sheet of the emergency stop relay.Please find the necessary information about the emergency stop in the operationmanual.Do you understand the different settings about the operation of the emergency stopwith one single station or with the whole mMS?

Notes about the emergency relays (equipment marking, function, indication):

Notes

Pages and the equipment marking of the emergency stop relays:

-

magazine station:

document page 8, PDF-page 11, equipment marking -8A1

- processing station with pneumatic press:


-

storage station:


The relay meets the following safety requirements:

-

The circuit is redundant with built-in self-monitoring.

-

The safety function remains effective in the case of a compo-nent failure.

- The correct opening and closing of the safety function relays is tested

automatically in each on-off cycle.

LED indicator for:

-

LED Power: Supply voltage

-

LED CH.1: Switch status channel 1

- LED CH.2: Switch status channel 2




Execution

Magazine Station – details about the emergency relay shut off:

Diagram




Magazine Station –¬ details about the equipment supplied by emergency stop relay:

Diagram




mMS – details about the emergency relay shut off and activation:

Diagram




Notes



2012-07-31 Schuettler | Exercise 2 - Calculation of the cylinder forces Bosch Rexroth AG 1/6

Calculation of the cylinder forces

Working with the documentation

Information

The modular Mechatronic System (mMS) consists of several moving parts. Very oftenthe actuator for this motion is a cylinder. You will find the statement in the operationmanual:

“Danger of injuryRisk of crushing by the many moving elements of the teaching system. Eventhough the pneumatic operating pressure is set to a maximum of 6 bar and thehydraulic operating pressure to 30 bar, fingers can be injured when reachingbetween fixed and moving parts.”(RE 09951-B, Chapter: 2.4 Remaining potential dangers)

The forces for the following devices have to be calculated:

a.

Pneumatic cylinders (extending) with the operating pressure:2SS-2A (Station 2, Pneumatic press processing station)2PP-3A (Station 2, Pneumatic press processing station)1VM1-2A (Station 1, Magazine station)

b. Create an additional diagram for the pneumatic cylinders in item a. Insert inthis a characteristic line, for each equipment in the extending force direc-tion, depending on the pressure and name them with the piston size. Insertthe pressure from 3 bar up to 10 bar on the X-axis and the forces form 0 Nup to 1000 N on the Y-axis.



2/6 Bosch Rexroth AG Exercise 2 - Calculation of the cylinder forces | 2012-07-31 Schuettler

Planning

Take the required technical data form the mMS cylinder ID plates.Are the searched physical quantities known?Are all the necessary formulas for the cylinder-force calculation known?Are all the necessary technical data known?

Insert the required technical data and formulas:

Notes

2

cm

N 60 bar 6 Pneumatic p

22 ASS-Piston

32 APP-Piston

211 AVM Piston

cm2,0mm20 d

cm3,2mm32 d

cm1,0mm10 d

A

F p

4

2

d A

4

2

d pF




Execution

Calculation to the exercise item a

Calculation

N1,474

)cm0,1(60 2

cm

N

21

2

AVM PistonF

N5,4824

)cm2,3(60 2

cm

N

32

2

APP-PistonF

N5,1884

)cm0,2(602

cm

N

22

2

ASS-PistonF

Calculation to the exercise item b

Calculation

N5,784

)cm0,1(100 2

cm

N

21

2

AVM PistonF

N2,8044

)cm2,3(100 2

cm

N

32

2

APP-PistonF

N2,3144

)cm0,2(1002

cm

N

22

2

ASS-PistonF




Pressure – Force - Diagram

Diagram

1

2

3

1: 1VM1-2A

2: 2SS-2A

3: 2PP-3A




Notes



2012-07-31 Schuettler | Exercise 3 - Tank filling device Bosch Rexroth AG 1/4

Tank filling device

basics about the Software Rexroth IndraLogic

Information

A tank filling plant consists of 3 tanks that are equipped with fill level switches. Thetank filling device is switched on using the S1 start button. For switching the deviceoff, the S2 stop button is used. For the "Full" notifications, the level switches S3, S5and S7 are used. For the "Empty" notifications, the signal encoders S4, S6 and S8 areused.The storage tanks can be arbitrary filled and emptied by hand. For the filling, thevalves Y1, Y2 and Y3 are used. There is a control to secure that after an "Empty" noti-fication occurred, only one tank can be filled. The filling of the tank continues until thecorresponding "Full" notification has appeared.

You will use a simulation for the execution of this exercise. The following picture will

show you the visualization of the simulation given in a IndraLogic project.

Fig: 01 Technology scheme of the exercise „Tank filling device“

Please find the simulation ready prepared in the IndraLogic project MISC000016.pro.To use the simulation you have to start your program coding and the whole sequencein PLC_PRG and you should not declare any additional task configuration.To see the visualization you have to open in the register “Visualization” the object:“DCA_tank_filling_device”.

If you want to test your coding, turn on the IndraLogic “Simulation Mode” in the menu

Online – Simulation Mode, then download the PLC program in the simulation PLCwith Online – Login. Now you have to set the PLC in operation mode RUN with

Online – Run. At last you have to start the simulation with a mouse click on the green

arrow in the upper right corner of the visualization.



2/4 Bosch Rexroth AG Exercise 3 - Tank filling device | 2012-07-31 Schuettler

In the electrical diagram you can find the wiring and address information about the

inputs and outputs of the PLC. You should take care of the sensor signals. The “Full”

and “Empty” notification will transfer a TRUE signal as long as the tank filling level isbetween minimum and maximum.

Fig: 02 Electrical diagram of the exercise „Tank filling device“



2012-07-31 Schuettler | Exercise 3 - Tank filling device Bosch Rexroth AG 3/4

The following programs have to be executed and tested with the simulation:

a.

Coding the program like an electrical diagram in the programming language Letter

Diagram (LD). Do not use a saving functionality of a Function Block Flip-Flop.

b. Coding the program by using a saving function of a Flip-Flop in the programming

language Function Block Diagram (FBD). Create your own Function Block Flip-

Flop for that.

c.

Coding the program by using the saving functionality of a Flip-Flop of the library

“Standard.LIB”. Choose the language LD or FBD you prefer.

d. Copy POU form item c. Change the program of the copied item that if all tanks are

empty at the same time the fill up process will start with tank 2, then tank 1 and at

last tank 3.

e. Coding the program that the filling process will be done in the same order like the

emptying process. That means, when the tanks become empty in the following or-

der: tank 1, tank 3, tank 2. And after that the system is started with the start button

S1 the filling sequence is similar to the emptying sequence: tank 1, tank 3, tank 2.

Planning

Open the IndraLogic project MISC000016.pro.

Start with the declaration of the global variables.

Insert for each exercise a folder in the register POUs with the names “Exercise_a” to

“Exercise_e”

Insert a POU in your first Folder and give it the name “Tank_filling_device_a” for the

first program with the description in item a.

For the programs of item b up to item e please insert for the coding also an own POU

in the prepared folder and control the using of the POU with a call command in the

POU PLC_PRG.

Test each program in the simulation.



4/4 Bosch Rexroth AG Exercise 3 - Tank filling device | 2012-07-31 Schuettler

Notes



2012-07-31 Schuettler | Exercise 4 - Local Area Network with PLCs Bosch Rexroth AG 1/6

Local Area Network with PLCs

Installation of the communication network

Communication directly between 1 PLC and 1 computer

Install a physical network between your computer and one PLC of the mMS Stations.

Feel free by the parameters of the following adjustments:-

IP address-

subnet mask

Check your communication with the command prompt.

Ethernet

Cross-Over cable

10

20

Notes

For the installation is a Ethernet cable necessary. For a direct communication

is a Ethernet Cross-Over-Cable necessary. Often the new integrated network

adapter are able to set a cross over automatically

Installation:

Subnet mask: 255.255.255.0

IP address: 192.168.10.1

Computer

Position 20:

Subnet mask: 255.255.255.0

IP address: 192.168.10.11

PLC Rexroth IndraControl L20

Position 10:

Different parameter values are also possible

The following parameters are examples.



2/6 Bosch Rexroth AG Exercise 4 - Local Area Network with PLCs | 2012-07-31 Schuettler

Communication via a Ethernet switch between 2 PLC and 2 com-

putersInstall a physical network between two computers and two PLCs of the mMS Stations.

Feel free by the parameters of the following adjustments:- IP address- subnet mask


E

t h e r n e t c a b l e

P o r t 1

P o r t 3

P o r t 2

P o r t 4

P o r t 5

10

Ethernet switch

E


E


Ethernet cable

30 31

20 21




Notes

Subnet mask: 255.255.255.0

Position 31:


IP address: 192.168.10.12

Subnet mask: 255.255.255.0

Installation:

For the installation are standard Ethernet cables necessary.


IP address: 192.168.10.11

Position 30:

Subnet mask: 255.255.255.0IP address: 192.168.10.2

Computer

Position 21:

Subnet mask: 255.255.255.0

IP address: 192.168.10.1

Computer

Position 20:

Different parameter values are also possibleThe following parameters are examples.




Communication via a router (+ Ethernet switch) between 3 PLC andsome computer

Install a physical network between several computers and three PLCs of the mMSStations.

Feel free by the parameters of the following adjustments:- IP address- subnet mask- DHCP


Position 11 (Router):-

DHCP Server enabled

-

DHCP IP Address Range 192.168.10.100 to 192.168.10.199

E t h e r n e t c a b l e

P o r t 1

P o r t 3

P o r t 2

P o r t 4

P o r t 5

Ethernet switch

W A N

P o r t 2

P o r t 1

P o r t 3

P o r t 4

Router

10 11



Ethernet Cross-Over cable

Ethernet cable


30 31 32

20 21

40 41 42 43




Notes

IP address: 192.168.2.12

Subnet mask: 255.255.255.0

Position 31:


IP address: 192.168.2.13

Subnet mask: 255.255.255.0

Installation:

For the installation are standard Ethernet cables necessary.

Position 31:


Subnet mask: 255.255.255.0

IP address: 192.168.2.11


Position 30:

DHCP

Computer

Position 20, 21, 40, 41, 42, 43:

______________________

Access key for the WLAN:

Different parameter values are also possibleThe following parameters are examples.




Notes



2012-07-31 Schuettler | Exercise 5 -Sequence of the magazine station Bosch Rexroth AG 1/8

Information

One cube half is pushed from the separating magazine one onto a conveyor belt by apneumatic cylinder. The conveyor belt moves it past the testing unit. A sensor at theend of the conveyor belt senses that a work piece has arrived, and the conveyor beltstops.For starting this sequence you have to push the start button one time and it shouldstop if the light barrier is interrupted.

The hardware configuration has also been done in IndraWorks. The following pictureshows you all the necessary details about the PLC and peripheries configuration. Fellfree to set the missing details on your own decision.

Sequence of the magazine station

Project administration and PLC programming

Fig: 01 IndraWorks project with the hardware declaration and parameters



2/8 Bosch Rexroth AG Exercise 5 -Sequence of the magazine station | 2012-07-31 Schuettler

Here you can see the sequence of the program.

Fig: 02

GRAFCET of the magazine program

The following programs have to be executed and tested with the magazine station:a. Coding the program to get the function of the GRAFCET description of the figure

above. In this first exercise you should use the set and reset function of the actionfrom each step.

b.

Add the following functions to the program:The conveyor belt stops to early. Add a step that will turn off the conveyor belt with0.5 second delay after the light barrier interrupted. Also change all Qualifiers to notstored, if it is possible.




c. Structure your program with the following operation modes (for an overview, usethe figure “Operation mode interrelationship “; OM = operation mode):- OM_Emergency:

Is set, if the emergency stop is activated. Is reset, if the emergency stop is de-activated and the quit button is pushed. During this OM all actuators shouldstop working.

- OM_SetInitialPos:Is set, if the quit button is activated and the system is in OM_Emergency orEM_BreakProcess. Is reset, if the start button is activated. During this OM allactuators should stop working. Set the emergency relay. Set the process se-quence in initial position.

-

OM_MoveInitalPos:Is set, if the start button is activated. The system is in OM_SetInitialPos andthe system is not in initial position. Is reset, if the start button is activated. Dur-

ing this OM all the actuators move in initial position.- OM_InProcess:Is set, if the start button is activated. The system is in initial mode and theOM_SetInitialPos or OM_MoveInitalPos is active. During this OM the processsequence is executed.

- OM_BreakProcess:Is set, if the stop button is activated and the system is in OM_InProcess. Isrested when the start button or the quit button is activated. During this OM theprocess is stopped

Fig: 03 Operation mode interrelationship




d. There is a work piece identification during the process sequence. Add all neces-sary coding to get an work piece result in an integer variable with the followingpossible values:

Dec Bin Description0 0 0 0 dark; no metal; open work piece side downwards1 0 0 1 dark; no metal; open work piece side upwards2 0 1 0 dark; metal; open work piece side downwards3 0 1 1 dark; open work piece side upwards; metal4 1 0 0 light; no metal; open work piece side downwards5 1 0 1 light; open work piece side upwards; no metal6 1 1 0 light; open work piece side downwards; metal7 1 1 1 light; open work piece side upwards; metal

d a r k / l i g h t

n o m e t a l / m e t a l

o p e n w o r k p i e c e s i d

e

d o w n w a r d s / u p w a r d

s

The result should be stored in a global value with the name intWorkPieceIdentifica-tion. Take care about the moment if the value is set and reset to the variable.

e. Add the library “RIH_CML20.lib” to the IndraLogic project. The result of the workpiece identification can be now shown in the IndraControl L20 display. Use astring variable which shows the work piece result as long as the cube half is inter-rupting the light barrier.

You will find information about the library on the documentation CD in the PDF file“Rexroth IndraControl L20 - System Description(R911312329).pdf”.

f.

Add the following function: The useable button indicators are flashing during eachoperation mode. The start button should shine during any move of an actuator.




Planning

Please create a new IndraWorks project and name it “MagazineStation_exercise_a”for the solution of item a. After finishing the first exercise item you should use thefunction File – Save as… from the standard menu of IndraWorks for the followingitems and give them the name “MagazineStation_exercise_” and add the item charac-ter.Begin with the hardware declaration and parameter settings in IndraWorks. Beforeyou will start testing the exercise with the magazine station, you have to compare theparameters of your declaration with the available hardware.In Indralogic you have to declare the variables at first. If you have done the hardwaredeclaration shown in the figure “IndraWorks project with the hardware declaration andparameters” you can use the following address list (necessary addresses signed with“” in the right column):

Onboard I/OsEquipmentDesignation

PLCAddress

Description, Logic assignment

--- IX0.2 Station 1 coupled with Station 2 =TRUE--- IX0.3 Station 1 get a signal from Station 2 =TRUE--- QX0.0 Station 1 set a signal to Station 2 =TRUE--- QX0.1 Station 1 set a signal to Station 2 =TRUE

-13K2 QX0.4 Couple relay is active =TRUE (activate emergencyrelay)

Control panelEquipmentDesignation

PLCAddress


--- IX1.0 Emergency stop relay activated =TRUE

+BP-S0 IX1.1 Switch Manual S0 activated =TRUE+BP-S0 IX1.2 Switch Auto S0 activated =TRUE+BP-S10 IX1.3 Button Start SH10 activated =TRUE

+BP-S11 IX1.4 Button Stop SH11 activated =FALSE

+BP-S12 IX1.5 Button Quit SH12 activated =TRUE

+BP-S6 IX1.6 Button SH6 =TRUE+BP-S8 IX1.7 Switch Emergency Stop S8 operated =TRUE

+BP-S1 IX2.0 Switch S1 activated =TRUE

+BP-S2 IX2.1 Switch S2 activated =TRUE+BP-S3 IX2.2 Switch S3 activated =TRUE+BP-S4 IX2.3 Switch S4 activated =TRUE+BP-S5 IX2.4 Switch S5 activated =TRUE

+BP-SH10 QX1.0 Indicator lamp Start SH10 active =TRUE

+BP-SH11 QX1.1 Indicator lamp Stop SH11 active =TRUE

+BP-SH12 QX1.2 Indicator lamp Quit SH12 active =TRUE

+BP-SH6 QX1.3 Indicator lamp SH6 active =TRUE




Conveyor beltEquipmentDesignation

PLCAddress


+FB-B1 IX5.0 Light barrier B1 interrupted =TRUE

+FB -K1 QX5.0 Conveyor belt move in processing direction =TRUE

+FB -K2 QX5.1 Conveyor belt move in sort out direction =TRUE

Magazine 1EquipmentDesignation

PLCAddress


+VM1-B1 IX6.0 Magazine 1, cylinder extended, sensor B1 =TRUE

+VM1-B2 IX6.1 Magazine 1, cylinder retracted, sensor B2 =TRUE

+VM1-S3 IX6.2 Magazine 1, empty, sensor S3 =FALSE+VM1-Y1 QX6.0 Magazine 1, cylinder retract, valve Y1 =TRUE

+VM1-Y2 QX6.1 Magazine 1, cylinder extend, valve Y2 =TRUE

Magazine 2EquipmentDesignation

PLCAddress


+VM2-B1 IX7.0 Magazine 2, cylinder extended, sensor B1 =TRUE+VM2-B2 IX7.1 Magazine 2, cylinder retracted, sensor B2 =TRUE

+VM2-S3 IX7.2 Magazine 2, empty, sensor S3 =FALSE+VM2-Y1 QX7.0 Magazine 2, cylinder retract, valve Y1 =TRUE

+VM2-Y2 QX7.1 Magazine 2, cylinder extend, valve Y2 =TRUE

Testing unit 2EquipmentDesignation

PLCAddress


+PE-B1 IX8.0 Work piece available, sensor B1 =TRUE

+PE-B2 IX8.1 Work piece open upward, sensor B2 =TRUE

+PE-B3 IX8.2 Work piece light, sensor B3 =TRUE

+PE-B4 IX8.3 Work piece metal, sensor B4 =TRUE

+PE-Y1 QX8.1 Testing unit cylinder retract, valve Y1 =TRUE

+PE-BY2 QX8.0 Testing unit cylinder extend valve Y2 =TRUE

For all coding it is necessary that you will take care of the emergency stop and alsothe emergency quit sequence with the couple relay.




Notes



1Project 03: PLC programming for el. conveyor belt Bosch Rexroth AG I RE 00852/09.07

03

Project 03 :

Project tasks

As part of the "electrical conveyor belt" project, the trainees are to learn andimplement application programming in IndraWorks/IndraLogic for the first time.This involves programming in sequential function chart as well as visualizationin IndraLogic for trying out in a simulation and on the actual mMS system.

Project definition

The electrical conveyor belt in Station 2 connects the material flow to the cubeassembly between the second station portal and the handling device of the thirdstation. In this project an aluminum or plastic cube half is placed manually onthe right end of the conveyor belt. After pressing "START" on the control panel,the cube half is to be transported to the left end of the conveyor belt, controlledby an IndraLogic program, which needs to be created. Then the conveyor beltis to be stopped by a sensor. When the cube half is removed, "QUIT" lights up.The removal must be acknowledged by pressing the "QUIT" button. Then, the

program returns again to the initial position.

Knowledge of electropneumatic and electrical components and basic PCskills.

Fig. 03.01 Station 2 Processing

Basic principles of PLC programming with L20

in the beginner's application for the electrical

conveyor belt in Station 2

Prerequisites




03

Project steps

• Analysis of project documents:

- Operating instructions "RE 09950-B" describe safety in chapter 2, andthe function of the Processing Station with pneumatic press in chapter3.3.

- In wiring diagram “R961000527 Processing PN.pdf” you can find theconveyor belt on pages 24 and 34 via page 3. Page 24 describes thedigital inputs of the conveyor belt and page 34 describes the digital

outputs of the conveyor belt. The digital inputs of the control panel areshown on pages 17 to 20, and the digital outputs of the control panelon page 30. The page numbers do not correspond to the page numbersof the document, but are those shown in the bottom right corner of thepage.

- Create a list of the equipment parts of Station 2:

→ +FB-M1 conveyor belt motor

→ +FB-K1 conveyor belt, clockwise relay

→ +FB-B1 conveyor belt, light button (optical, N/O)

→ +BP-SH10 control panel start button (N/O)

→ +BP-SH10 control panel start indicator lamp, green

→ +BP-SH12 control panel acknowledgement push-button (N/O)

→ +BP-SH12 control panel acknowledgement indicator lamp, blue

- The data sheets of the equipment can be found on the CD-ROM

"Technical documentation":




- The functions of the equipment are described in the data sheets:



→ +FB-K2 conveyor belt, counter-clockwise relay


Informing




03

• Project handling steps: - Select required equipment: electrical

- Describe individual functions: Operation, sensors, actuators,display

- Document the sequence of functions: Describe controlling

- IndraWorks: Create control project L20 with hardware mMS Station 2

- Create project for programming in IndraWorks

- Declare symbol names of inputs and outputs

- Create sequence program in SFC (sequential function chart)

- Generate PLC program

- Load and start PLC program in the control

- Test PLC program

Planning

- Identify the PLC inputs and outputs(see Annex Global_Variables_Station2.exp):

→

PLC inputs on slot R-IB IL 24 DI-4 -15A8 IX5.0 Light button

→ PLC inputs on slot R-IB IL 24 DI-4 -15A2.3 IX1.3 Start button

→ PLC inputs on slot R-IB IL 24 DI-4 -15A2.4IX1.5 Acknowledgement button

→ PLC outputs on slot R-IB IL 24 DO-4 -15A16QX5.0 Conveyor belt, clockwise

→ PLC outputs on slot R-IB IL 24 DO-4 -15A17

QX5.1 Conveyor belt, counter-clockwise → PLC outputs on slot R-IB IL 24 DO-4 -15A14

QX1.0 Start indicator lampQX1.2 Acknowledgement indicator lamp




03

Work instructions:

- Set up the programming workstation with IndraWorks and IndraLogic ona PC with an Ethernet connection

- Start IndraWorks, create a new project,Name = Project03ConveyorBelt, use project directory as suggested bythe program, language = English, representation: blank project tree

- Drag and paste IndraLogic L20 DP device with the mouse from the

library "Drive and Control" to the project tree; Device settings, next.Select version FWA-CML20-IL*-03VRS... .Select Profibus M, complete communication settings→ The project is initialized for IndraLogic, "+" opens Logic, Inline I/O,Profibus/M

- Move and add device "R-IL PB BK DP/V1 (DIP8 = OFF)" with the mousefrom the "Peripherals" library to the project tree, bus address = 5 Fromoutput %QB1, From input %IB1. The address entered as decimal numbermust be identical with the address on the Profibus coupler.Here, the address is set as bit pattern with eight switches.

Execution

Decision-

makingAids:

• PC with CD "Technical documentation"

• IndraWorks

• IndraLogic

Sequence and interrelationships of steps:

• See Planning

Teamwork :

• Preferably 2 trainees together

Solution process:

• Control hardware

• Control software

• Test




03

- Drag devices R-IB IL 24 DI16 (byte addresses: %IB1, %IB2), 8 timesR-IB IL 24 DI4 (byte addresses: %IB3, %IB4, %IB5, %IB9, %IB10,%IB11, %IB12, %IB13) and 9 times R-IB IL 24 DO4 (byte addresses:%QB1, %QB3, %QB4, %QB5, %QB9, %QB10, %QB11, %QB12,%QB13) using the mouse and add them to the project tree

Fig. 03.02 Project tree IndraWorks




03

The IndraLogic programming software must be set to "byte addressing".Check this as follows:

- Click with right mouse button on "Logic" icon, start IndraLogic- Resources/Target settings, right mouse button, Project database/Check

out

- Resources/Target settings, right mouse button, Process object/Gen-eral/TickBox Byte addressing/must be active/OK

- Resources/Target settings, right mouse button, Project database/Checkin

- Should you have made any changes:

- Close IndraLogic (to this end, move with the right mouse button to Logicin IndraWorks, Exit IndraLogic), close IndraWorks project, re-open In-draWorks Project03ConveyorBelt

- Re-open devices R-IB IL 24 DI16, etc. and "take over" the byte addressesabove

Fig. 03.03 %IX9.0 with byte address




03

• Create Program Organization Units (POU):

- First start IndraLogic.

- Right mouse button to POU, add object

- Select "Program" as type of POU, "sequential function chart (SFC)" aslanguage and name it "Sequence_Conveyor". The meaning of the POUwill be explained later.

The outputs q_Conveyor_belt_Clockwise_K1 andq_Conveyor_belt_Counter_clockwise_K2 must not be activated simultaneously.Observe the error messages while you are programming. We recommend work-ing with the Context Help in IndraWorks and IndraLogic (F1, Help/Content).

• What does "Sequence_Conyeyor" do?

The entire program code is contained in the "Sequence_Conyeyor" pro-gram. The program moves the conveyor belt to the left when the "START"(impulse) button is pressed and the conveyor belt continues to move (alsowithout pressing buttons) until the light button stops it. When the cube halfis removed from the conveyor belt, indicator lamp "QUIT" is switched on.Furthermore, the program can only be started again by pressing the "QUIT"button.

• What does PLC_PRG do?

PLC_PRG is created as first POU in a new project. It starts the execution,and from here, other POUs (programs, function blocks and functions) canbe called.In this case, the program "Sequence_Conveyor" is called up.

• Extending the POU

- The first diagram of a POU in SFC always consists of an “Init” action, a

subsequent transition “Trans0” and a jump back to “Init”. To do this, thediagram must be extended with additional steps. Firstly, the structure ofthe diagram must be defined. Then you can program the individual ac-tions and transitions.

- For every function status of the mechatronic system, a program step isrequired, i.e. for starting the motor, reaching the end of the conveyor beltand resetting the function assembly. Other steps are added by marking“Trans0” and selecting “Insert”, then “Step Transition” or using the but-tons on the control element.




03

Fig. 03.04 Control elements in SFC

Create a total of four additional steps. If you click directly on the name of atransition or a step, it is selected and you can change it. Name the first step

after “Init” “Start_Motor_Clockwise”, name the second “Belt_end”, name thethird “Workpiece_still_there” and the fourth “Reset".

After having created the steps, edit the actions, which are to be executed in theindividual steps. Go to the relevant step with the right mouse button and clickon “Associate action”. Two actions are only necessary for “Init” and “Start_Mo-tor_Clockwise”. One action is sufficient for the other steps.

Then select the “Resources” tab and open the “Global Variables” list. Importthe variables from the Global_Variables_Station2.exp file (see appendix) in the

following way:

- Object: select “Global Variables”, select the Project/Import menu, selectGlobal_Variables_Station2.EXP file in the directory; Open

The symbolic addresses and PLC addresses are then added as displayed inthe following picture.




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Fig. 03.05 Declaration of global variables

The name of the variable (e.g. i_Start_Button_SH10) is followed by the “AT”command and the IEC address beginning with a percentage sign. "I" standsfor an input and "Q" for an output. "X" (used in this example) stands for bit, and0.0 (0.1, 0.2 etc.) addresses the individual bits of output byte 0.

Now we can begin to define the individual actions. Always enter the command inthe first column of the action. "S" is used for Set and "R" for Reset. In the secondcolumn, the variable is used that is to be valid for the specific command.Apart from "S" and "R", further qualifiers are available.

Cf.: Online Help (F1) keyword "Qualifier"

In the “Init” step, use the actions “Set q_KR_Emergency_Stop” and “Set_q_ SH10_ML_Start”. After you have defined the steps, they are displayed as inthe following picture.




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Fig. 03.06 Step "INIT" with related actions

Remark:

Because the size of the field for the actions is limited, the complete designationwas added as comment.

For the further steps, the actions shown in the table will be declared:

Then the transitions must be defined. The transitions determine, which condi-tions must be fulfilled before jumping to the next step is possible. To do this,the names of the variables that enable these jumps must be added.

Add the following transitions:

After the “Init” step, “i_Start_Button_SH10” (pressing the start button),after the “Start_Motor_Clockwise”, “i_Light_Pushbutton_Sensor_B1” (lightsensor is triggered by passing workpiece),after the “Workpiece_still_there” step, “i_Acknowledgement_Button_SH12”(pressing the acknowledgement button),after the “Reset” step, “TRUE” (to return to “Init” step).

Table 03.01 Actions in the individual steps

In step Action

"Start_Motor_Clockwise" Set q_Motor_Conveyor_belt_Clockwise_K1

Reset q_SH10_ML_Start

"Belt_end" Reset q_Motor_Conveyor_belt_Clockwise_K1

"Workpiece_still_there" Set q_SH12_ML_Acknowledgement

"Reset" Reset q_SH12_ML_Acknowledgement




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In addition, after the “Belt_end” step you have to name and define the transitionas “Not_Light_pushbutton”. Click on “Zoom Action/Transition” with the rightmouse button, and in the window you opened, select “LAD” as the languageand confirm by pressing on “OK”. In Edit, press “Contact” then mark it andpress the “Negation” button. Select “???” and add the “i_Light_pushbut-ton_Sensor_B1” variable. Close the window.

As an alternative to the manual entry of variables, IndraLogic offers an entry aid.After having made your selection, press F2 and select the variables from the"Global variables" directory.

If you have completed everything correctly, the diagram should look as in thefollowing picture.

Fig. 03.07 SFC diagram

To complete the “PLC_PRG” program, go to the Edit window and enter “Se-quence_Conveyor”, then press “Return”. Now, programming is completed.




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Visualization of the program

The project variables can be quickly and easily animated using the IndraLogicvisualization function. In the following, add a picture for the conveyor belt anddraw in the "START" and "QUIT" control elements. The light barrier and themotor are also displayed to illustrate the switching processes.

Fig. 03.08. Visualization example

To create a visualization, first select the Visualization area in the Object Organizer.Click on the tab with the symbol called “Visualization” at the very bottomof the window on the left. Select the “Project” “Add Object” commands anda dialog opens. Enter the name “Conveyor Belt”. Confirm by pressing OK. Awindow appears where you can create your new visualization.




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For the conveyor belt visualization, it is recommended to proceed as fol-lows:

- Select “Insert” “Bitmap” or use the symbol in the menu bar. In the edit-ing window, draw a frame with the mouse for pasting your bitmap. You candetermine the size of the picture using this frame. Select the “Conveyor_belt.bmp” picture in the directory.

- Use the “Insert” “Ellipse” commands to draw a circle approx. two cm in size.Click on the edit field and change the circle to the correct size while holdingdown the left mouse button. Repeat this again so that you have two circlesin the picture.

- Double-click on one of the circles. This opens the dialog for editing the visu-alization elements.

- Select the Variables category and enter “q_SH10_ML_Start” in the “Changecolor” field. This means that the “q_SH10_ML_Start” global variable causesa change in color if the TRUE value is assigned. The point before the vari-able name indicates that it is a global variable. However, this point is notcompulsory.

- Then select the “Colors” category and click on “Interior” in the color area.Select a very neutral color such as white.

- Click on “Interior“ in the “Alarm Color” section and select green. The circleis white in its standard state. If the “q_SH10_ML_Start” variable has the

TRUE value, the color of the circle changes to green. Now the first part ofthe control panel is created.

- Then, select the “Text” category and enter START.

- Now the button is almost ready but it cannot yet be used. To allow this, checkthe “Button variable” in the “Enter” category and enter “i_Start_Button_SH10”in the blank field. Press “OK” to exit the dialog window.

“Button variable” means that by clicking on the visualization element, the TRUEvariable is set, and releasing the mouse resets it again to FALSE.




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To set up the acknowledgement button, that is to define the second circle,repeat the procedure with the following values:

- Blue as alarm color- Enter “QUIT"

- Enter the variables for the acknowledgement button; “q_SH12_ML_Acknowl-edgement” for the color change, change variable: “i_Acknowledgement_But-ton_SH12.

To visualize the motor, enter “Insert” “Ellipse” and draw a small circle.

You must also:

- Set red as the alarm color- Enter the text “Motor”

- Enter the motor variable for the color change; color change with “q_Mo-tor_Conveyor_belt_Clockwise_K1".

One button does not need to be set here as the Motor field should only showthat the motor is running.

For the visualization of “Remove Workpiece from Conveyor Belt”, carry out thesame steps as for the motor. However, use a rectangle instead of the circle.

You must also:

- Set the alarm color to yellow

- Enter the text “Extract Workpiece from Conveyor Belt”

- Add the “i_Light sensor_Sensor_B1” variable for the color change.

Lastly, you still have to visualize the light barrier. To do this use the “Insert”“Rectangle with rounded corners” commands. The setup follows the same

principle as for the "START" and "QUIT" buttons. However, you have to set upa switch instead of a button. As long as the workpiece interrupts the light bar-rier, the light barrier remains active and the program stops in the relevant step.The switch can be defined in the “Entry” category. Check the “toggle variable”."Toggle" means that the variable switches between <TRUE> and <FALSE>with every click of the mouse.




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As in the previous declarations, you also have to:

- Enter the “i_Light_button_Sensor_B1” variable for the button and color

change- Set an alarm color

- Enter the text "light sensor"

Once you have done this, move the elements in the picture to the correctplaces. The visualization is now completed and should look like on the follow-ing picture.

Fig. 03.09. Visualization example

Test the program in simulation mode

First, the program must be rebuilt ("Project" "Rebuild all"). Then select the com-mand Online/Simulation, load the program (Online/Log in) and start it. To thisend, execute Online/Start and set variable "i_Start_button_SH10" to <TRUE>.This is accomplished by double-clicking on the variable in the window showingthe global variables.




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Then the variable is to be assigned <TRUE>. Select <Ctl> <F7> or the “Online”“Write value” commands to set the value.

Press the “Start” button, and the program should now go to the next step andset the motor variable to <TRUE>. Now you have to set the start button to<FALSE> and the light barrier (“i_Light_button_Sensor_B1”) to <TRUE> bydouble-clicking on the start button. In this way you simulate that the workpiecehas reached the end of the conveyor belt.

Next, reset the light sensor to <FALSE> and then set the acknowledgement but-ton (“i_Acknowledgement_button_SH12”) to <TRUE>. This starts the programfrom the beginning. Lastly, reset the acknowledgement button to <FALSE>.

As you have created a visualization for your program, you can control the se-quence also by means of the operating elements of the visualization.

Test the program on the station

Firstly, insert a blank compact flash card into the PLC so that the existing masterprogram in the station is not overwritten.

To test the program on the station, remove the simulation tick (“Online”/“Simulation”) and load the program in the PLC (“Online”/“Log on”). Select

“Online”/“Start”. Now you can operate the program from the control panel onthe station.

In the case of communication errors, check the settings of the IP address onthe PC and the PLC and the settings of the communication parameters in In-draLogic.

When the program is ready and has passed the function test, you can archiveit as a zip file. Close IndraLogic (click with the right mouse button on “Logic”“Exit IndraLogic” in IndraWorks) and click with the right mouse button on "Pro-

ject03Conveyor” “Archive Project03Conveyor”.

Select "Archiving on file system" and confirm the selection. Then click "Next".In the following window, select the directory and the name for your archive andoptionally specify a password.Confirm this by clicking "Next".




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You should not enter a password. In the subsequent window, you can re-checkyour settings. If all settings are correct, click "Finish".

• Intermediate results:

- 0 errors, 0 warnings after "Rebuild project"

- Online\Log in was successful with loading of the project, Start

• Result/customer requirement:

- The movement of the cube half is started by pressing the Start buttonat the right end of the conveyor belt and is stopped by the light buttonat the left end of the conveyor belt.

Checking

• Self-evaluation by the trainee:

- Have you been able to carry out the basic project "conveyor belt" without

any faults?

- Have you understood the description of the operating sequences ofIndraWorks and IndraLogic in the project description?

- Have you understood the interrelationship between the assignment ofthe Profibus address and the parameterization of the I/O addresses inIndraWorks?

- Distinguish the terms "Action" and "Transition" in SFC programs ac-cording to IEC.

Evaluating




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• Evaluation by the trainer:

- Have the trainees successfully realized the visualization with the cor-

rect color changes during the execution of the program (Start buttongreen, motor red)?

- Have they parameterized the "light barrier" with "toggle variable"?

- Can the trainees correctly explain the terms "action" and "transi-tion"?

Exercises With Solution

Documents

Transcript of Exercises With Solution