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Hệ thống MPS của festo là 1 hệ sản xuất theo kiểu modun, được ứng dụng trong đào tạo nghề và công nghiệp. Đây là hệ mới của Festo có tính linh hoạt trong sản xuất và đào tạo kỹ năng nghề cơ điện tử, tự động hóa, IOT,
MPS500 Conveyor Manual Datum 28 April 2009 Ersteller Georg Kinder Version 1.0 Festo Didactic GmbH & Co KG Rechbergstr 73770 Denkendorf Germany www.festo.com/didactic Telefon 0711/3467-1424 Telefax 0711/34754-1424 E-Mail gkin@de.festo.com © Georg Kinder, Festo Didactic GmbH & Co KG MPS500 Conveyor system - 1 Station description - - Communication - I/O Communication - - 2 AS-Interface - 10 - 2 2 2 2 2 2 6 Technical specification - 10 AS-I communication run - 11 AS-I data transfer and transmission security - 12 AS-I connection example - 13 AS-I absolute hardware addresses within a S7 PLC program - 14 AS-I peripheral addresses regarding the slave addresses - 16 - Stations and drivers - 18 Driver handling - 18 - Driver setup - 19 - Conveyor Control - 24 Reading the carrier ID - 24 - Controlling the stopper - 25 - Data management - 27 ASI I/O communication in DB80 - 27 - Driver data in DB1 - 29 - Workpiece data in DB2 - 30 - Flowcharts - 31 OB100 - 31 - OB1 - 32 - FB1 - 34 - FB2 - 37 - FB3 - 40 - 6 FB4 - 44 - FB5 - 47 - FB6 - 51 - FB30 - 54 - 10 FB60 - 55 - 11 FB62 - 57 - 12 FB70 - 61 - -2 - © Georg Kinder, Festo Didactic GmbH & Co KG 13 FC10 - 62 - 14 FC50 - 63 - 15 FC51 - 64 - 16 FC90 - 65 - 17 FC91 - 66 - -3 - © Georg Kinder, Festo Didactic GmbH & Co KG MPS500 Conveyor system 1 Station description The conveyor is basically the brain of the MPS500 system Not only the material flow is controlled but also the handshakes to the MPS stations are started in the PLC of the conveyor system The program of the conveyor is designed to be quite flexible as it is possible to disconnect stations via software link and also to use stations at different index units (stopper positions) By default index/stopper units are present but they could be extended as the program is flexible in this regard Eight pallets are usually used to move workpieces on the conveyor Each pallet/carrier has a unique ID which is read at any index unit of the conveyor system The reading of the ID is simple as each carrier has drilling holes on its side Now in any of these holes a metallic pill can be inserted to which the inductive sensor at a stopper position reacts So when the inductive sensor detects a pill the counting starts, therefore ID+1 pills should be present in a carrier So if carrier ID = then pills need to be inside the drilling holes because the first pill is not counted but rather initiates the counting The transport system uses AC drives (230V) with a frequency converter to move the conveyors These are controlled by the PLC with an output The PLC itself uses I/O and AS-I communication within the conveyor system While direct I/O link cables are used for the communication between stations and conveyor system everything is connected to the AS-Interface Additionally an Ethernet network exists but it is only used for the WinCC visualization of the MPS500 process The WinCC application just reads and writes memory areas directly within the PLCs of the system The conveyor PLC doesn t use Ethernet for any communication tasks (e.g with index units or MPS stations) -4 - © Georg Kinder, Festo Didactic GmbH & Co KG Communication I/O Communication Direct I/O communication is used for the connected MPS stations The MPS stations are connected with a Syslink plug to the I/O terminal at each index unit The terminal itself is connected to the AS-I bus The robot and vision station are exceptional as their cables have a Syslink plug at both ends while for the other stations the MPS side of the cable splits in several 4mm connection cables The robot Syslink cable has a red mark while the one for the vision has a black one Between the MPS stations 4mm connection cables are used which are connected on the control panel of the MPS stations Also Senslink is used which is an optical information transfer It only works in one direction and only transmits one bit -5 - © Georg Kinder, Festo Didactic GmbH & Co KG I/O-communication Distribution station Testing station Conveyor station Distribution Station Testing Station PART AV Transport System PART ON PALLET PART AV TRANSPORT AS-i IN 0.7 IN 0.1 OUT 0.7 IN 0.7 IN 0.1 IN SYSLINK (AS-i) Station ready OUT OUT IN IN 0V IN IN OUT OUT 0V OUT OUT IN IN 0V IN IN OUT OUT 0V 0V IN IN OUT OUT 0V Stations ready Palette free 0V IN OUT OUT AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: IN 4mm Lab cable IN Signal SYSLINK OUT 0V 0V I/O-communication Processing station PICalfa station Conveyor station Processing Station PART AV PIC alfa Station Transport System PART AV Convert sensor to IN/ OUTPUT-Position dissemble el Push-out PART ON PALLET IN 0.7 IN 0.1 TRANSPORT AS-i OUT 0.7 IN 0.7 IN 0.1 OUT 0.7 No application for FMS50 IN SYSLINK (AS-i) Processing ready for part IN IN OUT OUT 0V OUT OUT IN IN 0V Rotation release 0V OUT OUT IN IN 0V IN IN OUT OUT 0V Run release Stations ready Pending order 0V IN IN OUT OUT 0V Part ready for IN OUT OUT IN 4mm Lab cable Signal IN OUT 0V 0V -6 - SYSLINK AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: © Georg Kinder, Festo Didactic GmbH & Co KG I/O-communication Vision system Conveyor station Vision Transport System PART ON PALLET TRANSPORT AS-i IN SIMATIC VS710 I/O-Terminal SYSLINK SYSLINK (AS-i) OUT0 OUT1 OUT2 OUT3 Station ready Part IO/ NIO (1/ 0) Quality evaluated Part NIO Pending order IN IN IN IN 0V 24V IN IN IN IN AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: OUT OUT OUT OUT 0V 24V AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: I/O-cabel twisted with SYS-Link-plug (black marking Order Nr 167 106) -7 - © Georg Kinder, Festo Didactic GmbH & Co KG I/O-communication Robot assembly Conveyor station Robot assembly station Transport System In FMS50 Mode the sensor signals PART AV and FOLLOWING STATION FREE are not transfered to the robot The released input is used for coding of the stations´orders (In6, In7) Foll.stat PART B2 B1 AV (colour)(Orient.)FREE I/O-Terminal Magazine I/O-Terminal Robot X1 PART ON PALLET Operation panel X3 X2 TRANSPORT AS-i IN IN IN IN IN IN IN IN 10 IN 11 IN 12 START STOP RESET IN PART AV FOLl stat Free 01: Assembly 10: Sorting out 11: at bus: load part on palette IN 14 IN 15 OUT X4 OUT OUT OUT OUT OUT OUT OUT 10 OUT 11 OUT 12 OUT 14 OUT 15 ERR CODE #0 ERR CODE #1 Order aktiv (busy) Station ready 0V SYSLINK (AS-i) OUT OUT OUT OUT IN IN IN IN 0V AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: I/O-cabel twisted with SYS-Link-plug (Red marking Order Nr 121 210 ) -8 - © Georg Kinder, Festo Didactic GmbH & Co KG I/O-communication ASRS Conveyor station Transport System Station AS/RS PART ON PALLET Pending order Bit1 Bit0 1 1 Control panel new X 0 1 X 1 Order No processing Reserved Storage Retrieval, oldest part Retrieval, jungest part TRANSPORT AS-i IN SYSLINK (AS-i) 0V OUT IN Pending order OUT OUT IN OUT IN Order Bit0 Order Bit1 Stock is full Stock is empty Order aktiv (busy) Station ready IN 0V OUT OUT OUT OUT AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: IN IN IN AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr: Cabel IN IN IN OUT OUT SYSLINK - plug SYSLINK OUT OUT 0V I/O-communication Sorting station PICalfa station Conveyor station PIC alfa station Transport System Sorting/Commissioning station PART AV PART AV OUT IN IN AS-I Addr: OUT 0.7 IN 0.7 IN 0.1 Transport System AS-i SYSLINK (AS-i) OUT OUT IN IN 0V FOL Stat FREE* Stations ready 0V OUT OUT IN IN 0V IN IN OUT OUT 0V Sorting station ready 0V OUT IN IN OUT 0V 4mm Labor cable Signal 0V Expiry as in the case of MPS standard: if a palette with workpiece is in Ap6 and the PIC alfa set signal free, the transport control sets share AV* the signal This signal must be evaluated in the program of the station PIC alfa instead of the signal share AV PIC alfa station get the part and the signal share AV* disappears again, the pallet can drive on AV* is a combination from the sensor share ON PALLET and the condition pallet IN position -9 - OUT OUT IN IN 0V Sorting Station not ready, if: - it wa s not sta rte d (START-Button a c tiva ted ) - slid es a re full with workp ie c es - no volta g e sup p lied to the sta tion - the sta tion d oes not e xist IN IN SYSLINK IN IN OUT OUT 0V © Georg Kinder, Festo Didactic GmbH & Co KG 2 AS-Interface The term "AS-I" derives from actuator-sensorinterface One could translate: interface between actuators, sensors and the PLC This bus system is a networking system for the lowest field level of the automation area - the process level On the process level, data throughput is very less, because interchange of signals of the connected devices (switches, buttons, BERO, contactor relays, solenoid valves etc.) is only binary However, demands on the rate of data transfer are very high 2 Technical specification The technical data and transmission protocol of the AS-Interface are fixed in the standard EN 50 295 Concerning the AS-Interface, the following data of performance are given: max 31 AS-i-participants with bit I/O effective data max 124 I/O sensors and actuators access procedure by cyclic polling at master-slave-procedure cycle time max 5ms error security, identification and repetition of interferred telegrams the medium of transmission is a simple two-core wire (2 x 1,5 mm²) for data and A auxiliary energy maximum for each AS-I string Supply voltage is 30 V DC The signal of the data transfer is modulated Additional supply of auxiliary energy 24 V DC is possible connection and mounting of AS-I components in throughput technology AS-i-slave-module with an integrated circuit (AS-i-chip), which are not in need of a processor and as well of no software Therefor results nearly non-delayed telegram processing and a small volume of the slaves special AS-I sensors and actuators with directly integrated AS-i-chips as well flexible construction opportunities like electric installation techniques length of wiring max 100m or 300m (with repeater) The AS-Interface is a single-master system Therefore, in a system, there is always existing one master and up to 31 slaves If there are further slaves necessary, another AS-Interface system with another master has to be installed - 10 - © Georg Kinder, Festo Didactic GmbH & Co KG - 52 - © Georg Kinder, Festo Didactic GmbH & Co KG - 53 - © Georg Kinder, Festo Didactic GmbH & Co KG FB30 - 54 - © Georg Kinder, Festo Didactic GmbH & Co KG 10 FB60 - 55 - © Georg Kinder, Festo Didactic GmbH & Co KG - 56 - © Georg Kinder, Festo Didactic GmbH & Co KG 11 FB62 - 57 - © Georg Kinder, Festo Didactic GmbH & Co KG - 58 - © Georg Kinder, Festo Didactic GmbH & Co KG - 59 - © Georg Kinder, Festo Didactic GmbH & Co KG - 60 - © Georg Kinder, Festo Didactic GmbH & Co KG 12 FB70 - 61 - © Georg Kinder, Festo Didactic GmbH & Co KG 13 FC10 - 62 - © Georg Kinder, Festo Didactic GmbH & Co KG 14 FC50 - 63 - © Georg Kinder, Festo Didactic GmbH & Co KG 15 FC51 - 64 - © Georg Kinder, Festo Didactic GmbH & Co KG 16 FC90 - 65 - © Georg Kinder, Festo Didactic GmbH & Co KG 17 FC91 - 66 -