Supervision of the Manipulator System (BMS)

Gran Sasso, 20/05/2003 OPERA Main meeting H. Pessard / 1

Supervision ofthe Manipulator System

(BMS)

What is Supervision for the Brick Manipulator System ? PLC programming and external interactions: task organisation

Task break-up, repartition of control between PLCs and Supervisor Brick loading and extraction schemes

Open questions in Supervisor realisation, perspectives programming language, packages, etc.

Supervision : P. Aygalinc (ESIA Eng. school), R. Gallet, M. Faivre, H. Pessard, F. Moreauin close contact with adjacent BMS activities:

Automate Programming development, Manipulation Database development


BMS control: What is supervision?

Brick Manipulation System based on 2 PLCs (industrial automats) one for each portico+platform on detector side independent operation on each side

PLCs (embarked PCs) can do complicated sequences: possibly oriented by sensor/communication events, but... once instructed to perform an operation, they will do it to the end

Need for a job analyser and PLC task sequencer: simplify programming

The BMS Supervisor (BMSS)

PLC #1

PLC # 2

wall side

corridor side


BMS control: Task Organisation

BMS Supervisor (BMSS)

perform ‘basic’ sequences

Industrial Automats (PLCs)

relates to outside world+

manages Manipulation DB

Brick Manipulator Manager (BMM) BMM

SupervisorOrganizes tasks

+ issues PLC commands

PLC #1 PLC #2

Ethernet link

Profibus link

Platform#2 instrumentation:

motors, sensors, etc.

Platform#1 instrumentation:

motors, sensors, etc.

simple actions


BMS control: Analysis of problem

Identify orders (informations) received by BMS from outside list possible jobs / global orders

Study detailed sequence of operations to be performed to accomplish job break task down to simple actions done by PLCs

choose a sensible repartition of control between PLCs and Supervision define basic sequences of simple actions = PLC’s controlled actions Ex.: brick train forming and pushing:

Pusher pushes brick trainjack pushes brickCarrousel rotates


Application to detector loading phase

Identify orders/info received from outside:“there is a basket full of bricks ready on side k”

Task break down: loop on basket level l :

dock platform to loading basket level l load 26 bricks onto carrousel decide which tray to fill next on side k

{wall#i, tray#j} in SM (external info from BMM) dock platform to {wall#i, tray#j} in SM push the 26 bricks in tray

Repartition of control between PLCs and Supervision above actions can be ‘basic sequences’ for PLCs


Loading phase specifics

Decision on which tray is to be filled next on a given side k : information from BMM based on

1) filling strategy, for ex.: Fill SM1, then SM2wall 31 to 1 (upstream in current SM)tray 64 to 1 (fill wall from top to bottom)2) detector filling current situation: database

consultation


Loading phase specifics Discovery:baskets should be filled differently for side #1 and side

#2 !

Wall side basket

Corridor side basket

Top view

Wall side BMS carrousel

Corridor side BMS carrousel


Application to brick exchange phase

Identify orders/info received from outside:“here is the list of target brick cells to be extracted and replaced”

Task break down: treat side#1 and side#2 separately (2 lists) treat SM1 and SM2 in sequence (simplify)

why? Passage between SM1 and SM2

--> 4 lists, each ~10 bricks/dayfor each list: look for brick depth max in list: can embark at most (32-d1max) r-

brickson trip #1 (at least 6 extractions can be done on a trip) dock loading basket level 6 and retrieve possible r-bricks (possibly

do it alternatively for SM1 and SM2) count additional number n of replacement bricks needed


Exchange phase simplified strategy

4 zones: SM1 and SM2 treated sequencially on each side 1 or trips per zone

Top view

SM1w-side

SM1c-side

SM2w-side

SM2c-side


Brick exchange phase (continued)

Task break down (slightly summarised): decide where to get replacement bricks {wall#i, tray#j,

pos#k1-kn} in SM to fill on side k (external info from BMM) dock platform to {wall#i, tray#j} in SM retrieve the n bricks from tray perform trip #1 (see details later) bring back the n extracted bricks to basket consider remaining list: compute new brick depth max in list, can

embark 32 - d2max= m replacement bricks (assuming no more r-bricks from basket)

decide where to get next m replacement bricks get them on carrousel perform trip #2 (see details below) and so on… (generally not more than 2 trips)


Exchange phase specifics

To decide which bricks on which tray to fetch to get replacement bricks in a given SM given side k :

information from BMM based on1) de-population strategy, for ex. in order: fetch r-bricks in top-plane, bottom plane, 1st planethen 2nd top plane, 2nd bottom plane, 2nd planethen 3rd top plane, 3rd bottom plane, 3rd plane2) detector depopulation situation: database consultation


Detector depopulation Note: 40 bricks/day x200days x5years = 40 000 bricksthis is more than 3 layers (top, bottom, upstream planes)3 layers = 38064 bricks

Side view

front view

More complicated to depopulate sides: need bricks to push brick rows in place+ potential mechanical problems if columns are empty


Exchange phase specifics (continued)

Conventions- basket: upper 4 levels = BMS reentering bricks lower 5 levels = BMS exiting bricks

basket positions are defined: 1 to 26- order of priority for r-bricks: 1/ get from basket

2/ get from detector to complete daily need Trip strategy (to reduce overall path and

moves):1) simple algorithm (could be more sophisticated if

significant gain demonstrated): see illustrationsex.: go to closest neighbour tray to serve2) carrousel rotations managing: see illustrations

Pos #1


Side view

Y

ZStarting point


Bricks are numbered from side of detector towards center from 1 to 26.Start point :Replacement bricks are on the carrousel.k : loop indexNbex : number of bricks to extract

manipulated bricks extracted bricks replacement bricks

Exemple of trip: max depth is 24, can embark 8 replacement bricks

Story of a trip (view from carrousel)


Starting point

K=1


K=1. Replace the 12th brick: the 11 first bricks are retrieved from tray Y= 11+8-1=18

K=1

turn carrousel by 32-18-1cases clockwise


Gap is placed in front of the bridge


12th brick is extracted

K=1

Last brick retrieved before the brick toextract


Rotate by 1 case clockwise

K=1


Introduce a replacement brick on the bridge

depth -1

K=1

Y=11+8-1=18

Rotate by 32-Ycases anti-clockwise to get depth-1 in front of bridge


depth -1

Red bricks are pushed back to place


K=1 finished, we go to another rowfor next extraction

K=2


K=2, go get the 5th brick: retrieve the first 4 on the carrousel

K=2

Y=4+8-2=10

Rotate by Y+1 anti-clockwise to have the gap facing the bridge


K=2

Gap is in front of bridge


depth-1K=2

The5th brick is extracted


Rotate by 1 case clockwise

r2

K=2


One replacement brickis pushed on the bridge

depth -1

K=2

Y=4+8-2=10

Rotate by Y cases clockwise to get depth-1facing the bridge


Depth-1 in front of bridge

depth-1

Red bricks are then pushed back

K=2


K=3

Next exchange K=3: to get the 24th brick retrieve the first 23 bricks


depth-1

K=3Rotate by 32-Y-1cases clockwiseto place gapin front of bridge

Y=23+8-3=28


depth-1

K=3

Gap is facing the bridge, 24th brick to be extracted


depth-1

K=3

The 24th brick is extracted

Then rotate by 1 case clockwise + push replacement brick on bridge


depth-1

K=3

Y=23+8-3=28Rotate by 32-Y casesanti-clockwise toget depth-1 facing bridge

Replacement brick on the bridge


depth-1

Red bricks are then pushed back in place

K=3


K=4


Now go get the 10th brick in another rowetc,etc...

K=4


BMS supervision: status of study

Break up done for main tasks (brick loading, brick extraction) with very simple algorithms till now

Choices in control repartition : master/slave relationships between BMM and Supervisor,

Supervisor and PLCs :

basic sequences

Global orders +infos procurement from DBBMM

SupervisorTasks break up +

PLC commands chaining

PLC #1 PLC #2


Basic tasks of PLCs: tentative list

Initialise system side k Move BM to loading station and dock it at level #i Load n bricks from loading basket onto carrousel Move BM to target row {SM#, wall#, tray#} and dock it to tray Push n bricks from carrousel into tray Push 1 brick out from carrousel to bridge Rotate carrousel: put case m in front of bridge Retrieve n bricks from tray to carrousel Unload n bricks from carrousel onto (un)loading basket

places m1 to mn places j1 to jn

and more (?)


BMS Supervisor tasksSupervisor tasks are now clearer:

Receive global order from BMM, acknowledge Break up task into basic PLC tasks Interrogate BMM when necessary to complete info:

next free brick row to fill next repl. bricks to fetch

Start sequence orders to PLCs For each order to a PLC:

report start of operation send order to PLC get report from PLC (operation result) report end of operation

Report on global order to BMM


Along Supervisor task processing

Supervisor will communicate with BMM along the way:

When a brick enters the BM system: passage basketcarrousel read codebars and report “ECC# w. CS# enters the BMS”

When n bricks are placed in target cells (multi-brick train pushed successfully into position): read CS codebar when CS passes on bridge report “ECC# w. CS# in target cell {SM#, wall#, tray#, pos.#}”

n times when brick train has arrived into position When n bricks are retrieved from a target tray:

report “ECC# w. CS# out of target cell {SM#, wall#, tray#, pos.#}”

n times when extraction operation will start read CS codebar while CS passes on bridge report “ECC# w. CS# (re)enters the BMS”


Along task processingSupervisor communication with BMM (continued):

When n bricks are unloaded: passage carrousel basket read codebars and report “ECC# w. CS# exits the BMS”

n times

The BMM will use these time-stamped informations to:

manage the MANIPULATION DATABASEcommunicate information to external OPERA systems

(see Dominique talk)


Perspectives BMS Supervisor study started March 2003:

significant work done: Task analysis and break up

Technical choices: communication with PLCs is done via a proprietary OPC Server

running on a PC under Windows code writing in an OPC Client : choices

Vijeo-Look commercial software tested: too limiteddevelop home-made C++ primitives: under

evaluationother possible option: LabVIEW-DSC

(‘BridgeVIEW’) under investigationPossibility: new version of PLC Ethernet interface

(w. integrated WEB services), skipping OPC layer?

Schedule: running version end of 2004

Supervision of the Manipulator System (BMS)

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