ciros mechatronics manual 1
DESCRIPTION
FestoTRANSCRIPT
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
8.3 Support via CIROS® Mechatronics _____________________ 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
9.3 Support via CIROS® Mechatronics _____________________ 187
9.4 Example _________________________________________ 188
9.5 Example _________________________________________ 197
Contents
© Festo Didactic GmbH & Co. KG „ 572757 5 5
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
6 © Festo Didactic GmbH & Co. KG „ 572757 6
© Festo Didactic GmbH & Co. KG „ 572757 7 7
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
1. What will you learn from the manual?
8 © Festo Didactic GmbH & Co. KG „ 572757 8
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
1. What will you learn from the manual?
© Festo Didactic GmbH & Co. KG „ 572757 9 9
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 .
10 © Festo Didactic GmbH & Co. KG „ 572757 10
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
© Festo Didactic GmbH & Co. KG „ 572757 11 11
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
3. These functions support you with the preparation of PC workstations for students
12 © Festo Didactic GmbH & Co. KG „ 572757 12
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
3. These functions support you with the preparation of PC workstations for students
© Festo Didactic GmbH & Co. KG „ 572757 13 13
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.
3. These functions support you with the preparation of PC workstations for students
14 © Festo Didactic GmbH & Co. KG „ 572757 14
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
3. These functions support you with the preparation of PC workstations for students
© Festo Didactic GmbH & Co. KG „ 572757 15 15
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.
16 © Festo Didactic GmbH & Co. KG „ 572757 16
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
4. The CIROS® Mechatronics system
© Festo Didactic GmbH & Co. KG „ 572757 17 17
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.
4. The CIROS® Mechatronics system
18 © Festo Didactic GmbH & Co. KG „ 572757 18
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
4. The CIROS® Mechatronics system
© Festo Didactic GmbH & Co. KG „ 572757 19 19
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
The process model represents a
simulation of the Festo Didactic
MPS B Processing Station. 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_B.mod
ProcessingStation_B(PLCSIM).
mod
ProcessingStation_B(EasyPort
).mod
Fluidic Muscle Press Station
The process model represents a
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
4. The CIROS® Mechatronics system
20 © Festo Didactic GmbH & Co. KG „ 572757 20
Process model Description File name
Handling Station
The process model represents a
simulation of the Festo Didactic
MPS Handling Station. In this
work cell, workpieces are to be
removed from a retainer and,
depending on the results of
material testing, deposited on a
slide. A sample PLC program is
available for this process model.
HandlingStation.mod
Stacker Store Station
The process model represents a
simulation of the Festo Didactic
Stacker Store. In this work cell,
workpieces are to be put into and
removed from storage. A sample
PLC program is available for this
process model.
StoreWorkCell.mod
Pick & Place Station
The process model represents a
simulation of the Festo Didactic
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
4. The CIROS® Mechatronics system
© Festo Didactic GmbH & Co. KG „ 572757 21 21
Process model Description File name
Testing Station
The process model represents a
simulation of the Festo Didactic
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
PLC program is available for this
process model.
TestingStation.mod
B Testing Station
The process model represents a
simulation of the Festo Didactic
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
program is available for this
process model.
TestingStation_B.mod
Note:
The process model can only
be controlled using the
internal PLC.
Buffer Station
The process model represents a
simulation of the Festo Didactic
MPS Buffer Station. In this work
cell, workpieces are to be
transported, buffered and
separated out. A sample PLC
program is available for this
process model.
BufferStation.mod
4. The CIROS® Mechatronics system
22 © Festo Didactic GmbH & Co. KG „ 572757 22
Process model Description File name
Sorting Station
The process model represents a
simulation of the Festo Didactic
MPS Sorting Station. In this work
cell, workpieces are to be sorted
according to material and colour.
A sample PLC program is
available for this process model.
SortingStation.mod
B Sorting Station
The process model represents a
simulation of the Festo Didactic
MPS B Sorting Station. In this
work cell, workpieces are to be
sorted according to material and
colour. A sample PLC program is
available for this process model.
SortingStation_B.mod
SortingStation_B(PLCSIM).mo
d
SortingStation_B(EasyPort).m
od
Separating Station
The process model represents a
simulation of the Festo Didactic
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
PLC program is available for this
process model.
SeparatingStation.mod
4. The CIROS® Mechatronics system
© Festo Didactic GmbH & Co. KG „ 572757 23 23
Process model Description File name
Distributing Station
The process model represents a
simulation of the Festo Didactic
MPS Distributing Station. In this
work cell, workpieces are to be
separated out and transferred to
the adjacent station. A sample
PLC program is available for this
process model.
DistributingStation.mod
B Distributing Station
The process model represents a
simulation of the Festo Didactic
MPS B Distributing Station. In this
work cell, workpieces are to be
separated out and transferred to
the adjacent station. A sample
PLC program is available for this
process model.
DistributingStation_B.mod
DistributingStation_B(PLCSIM
).mod
DistributingStation_B(EasyPor
t).mod
Rotary Indexing Table Module
The process model represents a
simulation of the Festo Didactic
MPS Rotary Indexing Table
module. In this work cell,
workpieces are to be tested and
polished in two parallel
sequences.
RotaryTable.mod
4. The CIROS® Mechatronics system
24 © Festo Didactic GmbH & Co. KG „ 572757 24
Process model Description File name
Stacking Magazine Module
The process model represents a
simulation of the Festo Didactic
MPS Stacking Magazine module.
In this work cell, workpieces are
to be separated out from the
magazine.
StackMagazine.mod
Changer Module
The process model represents a
simulation of the Festo Didactic
MPS Changer module. In this
work cell, workpieces are to be
picked up by a vacuum suction
cup and transferred by means of a
semi-rotary actuator.
ChangerModule.mod
Sorting System Project Module
The process model represents a
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
available for this process model.
SortingSystem.mod
4. The CIROS® Mechatronics system
© Festo Didactic GmbH & Co. KG „ 572757 25 25
Process model Description File name
Conveyor Project Module
The process model represents a
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
4. The CIROS® Mechatronics system
26 © Festo Didactic GmbH & Co. KG „ 572757 26
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
4. The CIROS® Mechatronics system
© Festo Didactic GmbH & Co. KG „ 572757 27 27
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
4. The CIROS® Mechatronics system
28 © Festo Didactic GmbH & Co. KG „ 572757 28
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
4. The CIROS® Mechatronics system
© Festo Didactic GmbH & Co. KG „ 572757 29 29
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
4. The CIROS® Mechatronics system
30 © Festo Didactic GmbH & Co. KG „ 572757 30
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
4. The CIROS® Mechatronics system
© Festo Didactic GmbH & Co. KG „ 572757 31 31
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.
32 © Festo Didactic GmbH & Co. KG „ 572757 32
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
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This is how you load a process model via CIROS® Mechatronics
Assistant
1. Start CIROS® Mechatronics .
Once CIROS® Mechatronics is started, both the View window and the
Help window are displayed.
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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.
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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
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36 © Festo Didactic GmbH & Co. KG „ 572757 36
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.
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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.
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3. Highlight the file DistributingStation.mod and click onto the Open
button.
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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
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40 © Festo Didactic GmbH & Co. KG „ 572757 40
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.
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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
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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
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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.
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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.
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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
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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.
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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.
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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.
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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.
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5. Important control functions of CIROS® Mechatronics
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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
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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
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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.
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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%.
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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
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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
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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.
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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.
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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.
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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.
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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.
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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.
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5. The Stop sign in the line in the Manual Operation window indicates
that a breakpoint is set at this signal.
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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.
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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.
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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
Operation in the Modeling menu.
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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.
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
Controlling a process
model via the external
Soft PLC S7-PLCSIM
Note
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 81 81
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
5. Important control functions of CIROS® Mechatronics
82 © Festo Didactic GmbH & Co. KG „ 572757 82
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. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 83 83
5. Download the desired PLC program in S7-PLCSIM by highlighting the
Modules folder. Then click onto Download in the menu Target
System.
5. Important control functions of CIROS® Mechatronics
84 © Festo Didactic GmbH & Co. KG „ 572757 84
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 85 85
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.
5. Important control functions of CIROS® Mechatronics
86 © Festo Didactic GmbH & Co. KG „ 572757 86
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 87 87
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
5. Important control functions of CIROS® Mechatronics
88 © Festo Didactic GmbH & Co. KG „ 572757 88
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 89 89
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.
5. Important control functions of CIROS® Mechatronics
90 © Festo Didactic GmbH & Co. KG „ 572757 90
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 91 91
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.
5. Important control functions of CIROS® Mechatronics
92 © Festo Didactic GmbH & Co. KG „ 572757 92
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
Controlling a process
model via the external
Soft PLC CoDeSys SP
PLCWinNT
Note
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 93 93
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
5. Important control functions of CIROS® Mechatronics
94 © Festo Didactic GmbH & Co. KG „ 572757 94
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
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 95 95
This is how you control a process model with CoDeSys SP PLCWinNT
1. Start CoDeSys and open the desired CoDeSys project.
5. Important control functions of CIROS® Mechatronics
96 © Festo Didactic GmbH & Co. KG „ 572757 96
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 97 97
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.
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98 © Festo Didactic GmbH & Co. KG „ 572757 98
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 99 99
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.
5. Important control functions of CIROS® Mechatronics
100 © Festo Didactic GmbH & Co. KG „ 572757 100
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 101 101
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.
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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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 103 103
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.
5. Important control functions of CIROS® Mechatronics
104 © Festo Didactic GmbH & Co. KG „ 572757 104
17. Select Dump symbol entries, then click on the configure symbol
file button.
This opens the Set object attributes window.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 105 105
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.
5. Important control functions of CIROS® Mechatronics
106 © Festo Didactic GmbH & Co. KG „ 572757 106
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 107 107
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.
5. Important control functions of CIROS® Mechatronics
108 © Festo Didactic GmbH & Co. KG „ 572757 108
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 109 109
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.
5. Important control functions of CIROS® Mechatronics
110 © Festo Didactic GmbH & Co. KG „ 572757 110
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.
29. Close the Switch external PLC <-> internal PLC window.
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 111 111
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
5. Important control functions of CIROS® Mechatronics
112 © Festo Didactic GmbH & Co. KG „ 572757 112
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 113 113
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.
5. Important control functions of CIROS® Mechatronics
114 © Festo Didactic GmbH & Co. KG „ 572757 114
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.
35. Minimise the EzOPC window.
36. Make sure that the process model simulation is active in CIROS®
Mechatronics.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 115 115
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.
5. Important control functions of CIROS® Mechatronics
116 © Festo Didactic GmbH & Co. KG „ 572757 116
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
Controlling a process
model via an external PLC
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 117 117
Possible configuration with a hardware PLC and two PCs
5. Important control functions of CIROS® Mechatronics
118 © Festo Didactic GmbH & Co. KG „ 572757 118
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 119 119
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
5. Important control functions of CIROS® Mechatronics
120 © Festo Didactic GmbH & Co. KG „ 572757 120
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 121 121
Configuration with PLC EduTrainer
5. Important control functions of CIROS® Mechatronics
122 © Festo Didactic GmbH & Co. KG „ 572757 122
Configuration with PLC board
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 123 123
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. Important control functions of CIROS® Mechatronics
124 © Festo Didactic GmbH & Co. KG „ 572757 124
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 125 125
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.
8. Close the Switch external PLC <-> internal PLC window.
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.
5. Important control functions of CIROS® Mechatronics
126 © Festo Didactic GmbH & Co. KG „ 572757 126
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 127 127
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
5. Important control functions of CIROS® Mechatronics
128 © Festo Didactic GmbH & Co. KG „ 572757 128
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 129 129
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.
5. Important control functions of CIROS® Mechatronics
130 © Festo Didactic GmbH & Co. KG „ 572757 130
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 131 131
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.
16. Minimise the EzOPC window.
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.
5. Important control functions of CIROS® Mechatronics
132 © Festo Didactic GmbH & Co. KG „ 572757 132
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
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 133 133
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
5. Important control functions of CIROS® Mechatronics
134 © Festo Didactic GmbH & Co. KG „ 572757 134
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
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 135 135
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. Important control functions of CIROS® Mechatronics
136 © Festo Didactic GmbH & Co. KG „ 572757 136
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 137 137
6. The selected faults are displayed in the Status column.
5. Important control functions of CIROS® Mechatronics
138 © Festo Didactic GmbH & Co. KG „ 572757 138
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 139 139
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
5. Important control functions of CIROS® Mechatronics
140 © Festo Didactic GmbH & Co. KG „ 572757 140
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.
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 141 141
3. The Fault Localisation window is displayed.
5. Important control functions of CIROS® Mechatronics
142 © Festo Didactic GmbH & Co. KG „ 572757 142
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. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 143 143
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
5. Important control functions of CIROS® Mechatronics
144 © Festo Didactic GmbH & Co. KG „ 572757 144
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
5. Important control functions of CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 145 145
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
146 © Festo Didactic GmbH & Co. KG „ 572757 146
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
6. The following training contents can be taught with CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 147 147
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
6. The following training contents can be taught with CIROS® Mechatronics
148 © Festo Didactic GmbH & Co. KG „ 572757 148
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
6. The following training contents can be taught with CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 149 149
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.
6. The following training contents can be taught with CIROS® Mechatronics
150 © Festo Didactic GmbH & Co. KG „ 572757 150
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.
Area of training 13:
Handover of mechatronic systems to
customers
To describe mechatronic systems.
To create operating instructions and documentation.
6. The following training contents can be taught with CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 151 151
Training content: PLC programming and testing of the program
Mechatronics engineers
Area of training Training aim
Area of training 7:
Realisation of mechatronic subsystems
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
complex mechatronic systems
To use computer-aided diagnostic methods, e.g. testing
and diagnostic functions of the programming system.
Area of training 11:
Commissioning, fault finding and
corrective procedures
To eliminate errors in the PLC program.
6. The following training contents can be taught with CIROS® Mechatronics
152 © Festo Didactic GmbH & Co. KG „ 572757 152
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:
Realisation of mechatronic subsystems
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
complex mechatronic systems
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.
Area of training 11:
Commissioning, fault finding and
corrective procedures
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.
6. The following training contents can be taught with CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 153 153
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
CIROS® Mechatronics
6. The following training contents can be taught with CIROS® Mechatronics
154 © Festo Didactic GmbH & Co. KG „ 572757 154
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.
© Festo Didactic GmbH & Co. KG „ 572757 155 155
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
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
156 © Festo Didactic GmbH & Co. KG „ 572757 156
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
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 157 157
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
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
158 © Festo Didactic GmbH & Co. KG „ 572757 158
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?
‟ Circuit diagrams
‟ Data sheets
Questions
Documents
Questions
Documents
Questions
Documents
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 159 159
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?
‟ Circuit diagrams
‟ 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?
‟ Circuit diagrams
‟ Data sheets
Questions
Documents
Questions
Documents
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
160 © Festo Didactic GmbH & Co. KG „ 572757 160
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
CIROS® Mechatronics
7.4
Example
Exercise
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 161 161
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
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
162 © Festo Didactic GmbH & Co. KG „ 572757 162
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“.
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 163 163
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
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
164 © Festo Didactic GmbH & Co. KG „ 572757 164
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.
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 165 165
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.
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
166 © Festo Didactic GmbH & Co. KG „ 572757 166
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.
Answer the following questions:
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
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 167 167
1. Load the Distributing process model. Make sure that the process
model is controlled via the internal PLC using the sample PLC
program. This applies in the case of the reference models.
Implementation
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
168 © Festo Didactic GmbH & Co. KG „ 572757 168
2. Refer to the technical documentation for information regarding the
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“.
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 169 169
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
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
170 © Festo Didactic GmbH & Co. KG „ 572757 170
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
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 171 171
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?
1. Load the Distributing process model. Make sure that the process
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
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
172 © Festo Didactic GmbH & Co. KG „ 572757 172
2. Refer to the technical documentation for information regarding the
signal and energy flow of the sensor 1B1 and the PLC output 3M1.
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 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. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 173 173
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.
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
174 © Festo Didactic GmbH & Co. KG „ 572757 174
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.
7. This is how you establish the mode of operation and structure of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 175 175
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.
176 © Festo Didactic GmbH & Co. KG „ 572757 176
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
8. This is how you establish the mode of operation of the components forming part of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 177 177
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.
General training aims
8.2
Methods
8.3
Support via
CIROS® Mechatronics
8. This is how you establish the mode of operation of the components forming part of a system in CIROS® Mechatronics
178 © Festo Didactic GmbH & Co. KG „ 572757 178
Investigating the mode of operation of the ejecting cylinder in the
stacking magazine module
Investigate the mode of operation of the stacking magazine.
Answer the following questions:
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
8. This is how you establish the mode of operation of the components forming part of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 179 179
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
8. This is how you establish the mode of operation of the components forming part of a system in CIROS® Mechatronics
180 © Festo Didactic GmbH & Co. KG „ 572757 180
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“.
8. This is how you establish the mode of operation of the components forming part of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 181 181
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
8. This is how you establish the mode of operation of the components forming part of a system in CIROS® Mechatronics
182 © Festo Didactic GmbH & Co. KG „ 572757 182
5. Open the Manual Operation window by clicking onto Manual
Operation in the Modeling menu.
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
8. This is how you establish the mode of operation of the components forming part of a system in CIROS® Mechatronics
© Festo Didactic GmbH & Co. KG „ 572757 183 183
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. This is how you establish the mode of operation of the components forming part of a system in CIROS® Mechatronics
184 © Festo Didactic GmbH & Co. KG „ 572757 184
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.
© Festo Didactic GmbH & Co. KG „ 572757 185 185
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
9. This is how you use CIROS® Mechatronics in PLC programming
186 © Festo Didactic GmbH & Co. KG „ 572757 186
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
9. This is how you use CIROS® Mechatronics in PLC programming
© Festo Didactic GmbH & Co. KG „ 572757 187 187
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
9. This is how you use CIROS® Mechatronics in PLC programming
188 © Festo Didactic GmbH & Co. KG „ 572757 188
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®
Mechatronics Assistant.
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
9. This is how you use CIROS® Mechatronics in PLC programming
© Festo Didactic GmbH & Co. KG „ 572757 189 189
Implementation using the programming system STEP 7and the Soft
PLC S7-PLCSIM
1. Start CIROS® Mechatronics .
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.
9. This is how you use CIROS® Mechatronics in PLC programming
190 © Festo Didactic GmbH & Co. KG „ 572757 190
3. Use the technical documentation to find out how the initial position
of the station is defined.
To do so, open the on-line help for the process model and click onto
Help on Workcell in the Help menu.
You will find the required information in the chapters „The
Distributing Station“ and „Technical Documentation“.
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
9. This is how you use CIROS® Mechatronics in PLC programming
© Festo Didactic GmbH & Co. KG „ 572757 191 191
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.
10. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto
the MRES button in the CPU 300/400 window.
9. This is how you use CIROS® Mechatronics in PLC programming
192 © Festo Didactic GmbH & Co. KG „ 572757 192
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
9. This is how you use CIROS® Mechatronics in PLC programming
© Festo Didactic GmbH & Co. KG „ 572757 193 193
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.
9. This is how you use CIROS® Mechatronics in PLC programming
194 © Festo Didactic GmbH & Co. KG „ 572757 194
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.
9. This is how you use CIROS® Mechatronics in PLC programming
© Festo Didactic GmbH & Co. KG „ 572757 195 195
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.
17. Minimise the EzOPC window.
18. If your PLC program is correct, the indicator light P1 is illuminated if
the station is in the initial position.
9. This is how you use CIROS® Mechatronics in PLC programming
196 © Festo Didactic GmbH & Co. KG „ 572757 196
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.
9. This is how you use CIROS® Mechatronics in PLC programming
© Festo Didactic GmbH & Co. KG „ 572757 197 197
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®
Mechatronics Assistant.
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
9. This is how you use CIROS® Mechatronics in PLC programming
198 © Festo Didactic GmbH & Co. KG „ 572757 198
Implementation using the programming system STEP 7 and the Soft
PLC S7-PLCSIM
1. Start CIROS® Mechatronics .
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.
9. This is how you use CIROS® Mechatronics in PLC programming
© Festo Didactic GmbH & Co. KG „ 572757 199 199
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.
9. This is how you use CIROS® Mechatronics in PLC programming
200 © Festo Didactic GmbH & Co. KG „ 572757 200
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
9. This is how you use CIROS® Mechatronics in PLC programming
© Festo Didactic GmbH & Co. KG „ 572757 201 201
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
9. This is how you use CIROS® Mechatronics in PLC programming
202 © Festo Didactic GmbH & Co. KG „ 572757 202
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.
10. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto
the MRES button in the CPU 300/400 window.
9. This is how you use CIROS® Mechatronics in PLC programming
© Festo Didactic GmbH & Co. KG „ 572757 203 203
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
9. This is how you use CIROS® Mechatronics in PLC programming
204 © Festo Didactic GmbH & Co. KG „ 572757 204
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.
9. This is how you use CIROS® Mechatronics in PLC programming
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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.
9. This is how you use CIROS® Mechatronics in PLC programming
206 © Festo Didactic GmbH & Co. KG „ 572757 206
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.
17. Minimise the EzOPC window.
18. If your program is correct, you can start the sequence once you have
inserted a workpiece by clicking onto the Start button.
9. This is how you use CIROS® Mechatronics in PLC programming
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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.
208 © Festo Didactic GmbH & Co. KG „ 572757 208
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
General training aims
10. This is how you carry out systematic fault finding on a simulated system
© Festo Didactic GmbH & Co. KG „ 572757 209 209
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
10. This is how you carry out systematic fault finding on a simulated system
210 © Festo Didactic GmbH & Co. KG „ 572757 210
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
10. This is how you carry out systematic fault finding on a simulated system
© Festo Didactic GmbH & Co. KG „ 572757 211 211
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.
10. This is how you carry out systematic fault finding on a simulated system
212 © Festo Didactic GmbH & Co. KG „ 572757 212
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
10. This is how you carry out systematic fault finding on a simulated system
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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
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214 © Festo Didactic GmbH & Co. KG „ 572757 214
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
10. This is how you carry out systematic fault finding on a simulated system
© Festo Didactic GmbH & Co. KG „ 572757 215 215
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
10. This is how you carry out systematic fault finding on a simulated system
216 © Festo Didactic GmbH & Co. KG „ 572757 216
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
10. This is how you carry out systematic fault finding on a simulated system
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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
10. This is how you carry out systematic fault finding on a simulated system
218 © Festo Didactic GmbH & Co. KG „ 572757 218
6. A fault has occurred during execution, which stops the process.
10. This is how you carry out systematic fault finding on a simulated system
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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
Distributing Station“ and „Technical Documentation“.
10. This is how you carry out systematic fault finding on a simulated system
220 © Festo Didactic GmbH & Co. KG „ 572757 220
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
10. This is how you carry out systematic fault finding on a simulated system
© Festo Didactic GmbH & Co. KG „ 572757 221 221
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
10. This is how you carry out systematic fault finding on a simulated system
222 © Festo Didactic GmbH & Co. KG „ 572757 222
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
10. This is how you carry out systematic fault finding on a simulated system
© Festo Didactic GmbH & Co. KG „ 572757 223 223
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
10. This is how you carry out systematic fault finding on a simulated system
224 © Festo Didactic GmbH & Co. KG „ 572757 224