Académique Documents
Professionnel Documents
Culture Documents
Advanced
Manual
698776 EN
09/2006
Order No.: 698776
Status: 09/2006
Authors: Christine Löffler
Graphics: Doris Schwarzenberger
Layout: 00.00.2005, Beatrice Huber
What is COSIMIR® PLC COSIMIR® PLC Advanced is a PC based graphic 3D simulation system for
Advanced? distributed automation systems. These systems consist of different,
internetworked, intelligent stations. The distributed systems represent
automation processes of varying complexity.
In the documentation and software, these systems are also referred to
as process models or workcells.
The simulated systems are also available as actual systems. With these
you can successfully apply and consolidate the knowledge gained on
the virtual automation systems using actual systems.
Structure of the manual The manual is divided into the following subject areas:
• Chapter 2 contains information and instructions regarding the
installation of COSIMIR® PLC Advanced.
• Chapters 3 and 4 describe the system and the main operational
functions of COSIMIR® PLC Advanced.
• Chapter 5 deals with the didactic aspects and lists the training
contents taught with COSIMIR® PLC Advanced. It further represents
the training concept and the resulting possibilities for use in
lessons.
• Chapters 6 and 7 describe actual problems in relation to the training
contents, methodological procedures towards solutions and
implementation in COSIMIR® PLC Advanced.
Conventions Specific notation is used for texts and key combinations and key
sequences to help you find information more easily.
Notation Meaning
Bold This format is used for command names, menu names, dialog box names,
directory names and command options.
Key1+key2 A plus symbol (+) between the key names means that the keys quoted must
be pressed simultaneously.
Key1–key2 A minus symbol (-) between the key names means that the keys quoted must
be pressed in sequence.
Additional support Further descriptions and support is available via the online Help. The
online Help consists of:
• COSIMIR® Help for operation and
• COSIMIR® PLC Advanced Assistant.
The menu of the online Help provides functions that you are already
familiar with from a standard Internet browser. These include: Next and
Back, Select Home Page, Print Selected Topics, Show/Hide the
Navigation bar or Set Options for Internet Connection.
Moreover, via extension registers such as Content, Search, Favourites,
you also have the option of conveniently navigating through the
information in COSIMIR® PLC Advanced Help.
Our telephone hotline is available at any time, should you have any
queries during the installation or operation of COSIMIR® PLC Advanced.
2.1 The system requirements for COSIMIR® PLC Advanced are specified.
System requirements
The system requirements for a PLC programming system are not taken
into consideration. You will need a PLC programming system if you
create your own PLC programs for the process models.
Graphics card Card with 3D acceleration and OpenGL support, 128 MB RAM
Interfaces USB interface for license plug with single user license or USB interface on
server with network license
2.2 You will be using COSIMIR® PLC Advanced as a single user license and
Installation of COSIMIR® operating COSIMIR® PLC Advanced strictly on one PC; the dongle is
PLC Advanced as single plugged into this PC.
user license The COSIMIR® PLC Advanced software can of course also be installed on
different PC workstations.
Note The WIBU dongle, which authorises the execution of COSIMIR PLC
Advanced, requires certain drivers. If the drivers are not available on
your PC, you will be requested to install or update these drivers. Follow
the instructions on the screen. As soon as the drivers for the WIBU
dongle are available on your PC, the licensing of COSIMIR PLC Advanced
will be carried out as the next step.
9. Now select the user group for which you wish to install COSIMIR®
PLC Advanced. Then click onto Next.
Note You should always select an installation directory which does not
contain any other versions of COSIMIR®.
11. Specify the program manager group in which the COSIMIR® PLC
Advanced symbols are to be stored. Festo Didactic is specified by
default as program manager group. You can of course rename this.
Confirm your selection by clicking onto Next.
12. COSIMIR® PLC Advanced is now ready for installation. Click onto
Start to start the installation.
13. The Start window of COSIMIR® PLC Advanced is now displayed. Click
onto Next.
14. You can install COSIMIR® PLC Advanced using two different options.
These options are: COSIMIR® extensions as well as robot and PLC
languages. We implicity recommend that you accept the preset
selection. The installation will be executed as soon as you click onto
Next.
15. If you click onto the Options button for the COSIMIR® Kernel
selection, the following window will be displayed. Click onto OK to
close the window again.
17. Click onto Finish when you receive confirmation that the installation
of installation of COSIMIR® PLC Advanced has been successfully
completed.
2.3 The concept of network installation relates mainly to the licensing of the
Network installation of software. With network installations, the software is made available via
COSIMIR® PLC Advanced a network and a central license server.
The network license installation data can also be found in the Network
directory on the installation CD of COSIMIR® PLC Advanced.
If you are working with the default settings of COSIMIR® PLC Advanced,
the prepared sample PLC program is automatically downloaded to the
internal PLC and executed once simulation is started. This enables you
to simulate the sample systems provided and any newly created system
straight away and without errors.
If you wish to modify one or several sample PLC programs, then the PLC
programs must be installed in an additional subdirectory specified by
you, where you can effect your changes. You can then download the
modified programs to the appropriate station of your system and
execute these. You can of course also download the modified PLC
programs to an external PLC, in which case the respective station of the
system using an external PLC.
The program The program SetupSamples.exe enables you to copy a few sample
SetupSamples.exe systems and the prepared S7 projects for the control of individual
stations to a user-defined directory on your PC.
• The setup program SetupSamples.exe installs the sample systems
and S7 projects provided to a computer or a network path.
• The installation directory is freely selectable.
• The computer does not require any administration rights.
This is how you install the prepared sample systems and S7 programs
OPC-Client
EzOPC (OPC-Server)
Easy S7-PLCSIM
Port
External
PLC
In order to ensure that the stations of the system interact correctly, they
need to exchange information.
The default communication links used between the stations are
established automatically.
In the next step you can establish or change the communication links
yourself and make the necessary adjustments in the PLC programs.
A further focal point is the creation of your own PLC programs for
individual stations. These PLC programs are downloaded to an external
PLC and COSIMIR® PLC Advanced exchanges the input/output signals
with the external PLC via the OPC interface.
COSIMIR® PLC Advanced requires the software program EzOPC for the
link to an external PLC. The OPC server EzOPC communicates with any
PLC via the EasyPort interface.
Note Please note: EzOPC is not installed automatically with the software
program COSIMIR® PLC Advanced. Install this program from the CD-
ROM provided if required.
3.2 Systems can be created from one or several stations. Each station
A distributed system in represents an "intelligent unit", which independently executes specific
COSIMIR® PLC Advanced machine functions.
An "intelligent unit" consists of a station, a predefined sequence with
predefined communication interface, a PLC program, an internal PLC
and an optional robot program. The predefined sequence of the PLC
controlled stations can of course be modified by the user.
Two types of system can be created from the stations listed above:
• MPS® Standard systems,
• MPS® 500-FMS systems.
Note A system can also be configured of only one station. This enables you to
teach all the training contents for which only one individual station is
required.
If changes are made in the communication link, you need to make sure
that the PLC programs of the respective stations make available the
communication information accordingly and conversely also evaluate it
again.
Processing station
Handling station
Storing station
Testing station
Buffer station
Robot station
Sorting station
Separating station
Distributing station
When you start the simulation of a system, the internal PLC executes the
sample PLC program forming part of the station. This enables you to
familiarise yourself with the running of a system immediately after
modelling in the simulation.
Detailed information regarding the functional scope of the internal PLC
can be found on the COSIMIR® online Help.
3.6 If you are creating and testing your own PLC programs for the individual
Controlling a station with stations of a system, we recommend that you download the programs
external PLC to an external PLC and execute them from this. The advantage of this is
that you can use the PLC and the programming system of your choice.
Also, the testing and diagnostic functions provided by the programming
system are thereby available to you in the PLC program for fault finding.
This includes the status display of PLC input/outputs and variables, the
online display of the PLC program and also the read-out of machine
statuses.
You do not need any additional hardware components if you use the
Soft-PLC S7-PLCSIM as external PLC.
If you use a hardware PLC as external PLC, you will need 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 EzOPC
via the serial interface of the PC. The OPC server passes on the data to
the selected station during the system simulation and, conversely, the
statuses of the sensors and actuators of the corresponding station are
communicated to the external PLC.
EasyPort
PLC
The task for trainees is to identify and describe the fault occurring
during system operation and to subsequently determine the cause of
the fault. The trainees enter the suspected fault in the dialog box for
error elimination. If the fault has been correctly identified, the system
then operates correctly. The entries in the dialog box for fault
elimination are logged and can be viewed by trainers and teachers.
3.8 With COSIMIR® PLC Advanced, you have numerous options to monitor
Functions for analysing a and analyse the operation of a system.
system
As soon as system simulation is active and the PLC programs of the
individual stations control the operation of the system, you can operate
and visually monitor the process.
The process is controlled via the pushbuttons and switches of the
individual control consoles.
• LEDs on the sensors and valves indicate the electrical status of the
process components.
• LEDs on the PLC inputs and outputs on the control console indicate
the status of the communication realised via these inputs and
outputs.
• If compressed air is applied to a cylinder connection, then the
connection is highlighted in blue. The compressed air tubing itself is
not simulated.
• The statuses of the PLC inputs/outputs are shown in separate
windows.
If you want to execute the sequence step-by-step, then use the Manual
Operation window as tool for control. By setting stops, you can stop the
process at defined points.
If a PLC program is not active during system simulation, you can use the
Manual Operation window to activate individual process activities,
whereby you can for example control the movement of a cylinder or the
switching on or off of an electric motor.
3.9 Here you obtain information about the directory and file structure of
Directory and file COSIMIR® PLC Advanced.
structure of COSIMIR® This information is useful if,
PLC Advanced • You want to make available the model of a system to other users,
• You want to modify the sample PLC programs for the individual
stations of a system.
Directory structure The following directory structure is created if you install COSIMIR® PLC
following the installation Advanced with the default settings offered.
of COSIMIR® PLC
Advanced
Programs
COSIMIR
PLC
Advanced
bin
FD_PLC_ADV
IRL
MB4
S7
313c___1 PLC programs
for MPS 500-FMS
stations
FMS50__1 PLC program
for MPS 500-FMS
transport system
MPSC_V22 PLC programs
for MPS Standard
stations
Store PLC program
for MPS 500-FMS
automated warehouse
LIB station
malfunction
Samples
Models
MPS500-FMS51 MPS 501-FMS system
Model Workcell for
MPS 501-MPS system
Programs PLC program for
MPS 501-FMS system
MPS500-FMS57 MPS 507-FMS system
MPS System MPS Standard system
with separating with separating station
Multi-Bit-IO
MPS VE-PR MPS Standard system
with distributing and
testing stations
Model
Programs
One-Bit-IO
MPS VE-PR MPS Standard system
with distributing and
testing stations
MPS VE-PR-SO MPS Standard system
with distributing and
testing stations
Programs PLC and robot
programs for
all MPS stations
The S7 project with the sample PLC programs for the individual stations
is stored in the directory S7. These original PLC programs must not be
modified!
If you want to modify one or several of the sample PLC programs, you
need to install the PLC programs in another subdirectory defined by
you, where you carry out your modifications. You can then download
the modified programs to the internal PLC of the appropriate station and
execute it.
With this procedure, the default PLC programs used by COSIMIR® PLC
Advanced remain unchanged and can be reloaded again to the internal
PLC of a station at any time.
Project structure for the The example of a system is used to show what files form part of a
modelled systems modelled system and what information is stored in these files. A system
is also known as a process model or workcell. All files which are part of
the graphic representation of the system are filed in the user-defined
subdirectory.
File Description
*.bmp Various bitmap files required for the graphic display of the system. The
bitmap files required are dependent on which stations are used in the
system.
A system also includes PLC programs, which are executed either via an
internal or external PLC. These PLC programs control the running of
individual system stations. The file *.ini includes a reference to the
memory location of the PLC programs.
You need to keep this in mind if you want to copy a system you have
modelled yourself to another PC and simulate from there.
If you want to copy the process model of a system, the best way to
proceed is as follows:
• Select all the files forming part of the system. These are all the files,
which have the name of the respective system and all the bitmap
files.
• Copy the selected file to a subdirectory of the desired PC. The
subdirectory on the target PC must have the same name and the
same path as on your PC.
• If the station is operated using the sample PLC programs, make sure
that the sample PLC programs on the new PC are stored in the same
path as on your PC. If this is not the case, start COSIMIR® PLC
Advanced on the new PC and download the copied process model.
Then download the desired PLC program from the relevant directory
on the new PC to the internal PLC of the individual system stations.
By downloading the PLC programs, the reference in the ini file to the
memory location of the PLC programs is automatically corrected.
The system can now be simulated.
• If one or several stations of the system are controlled via your own
created PLC programs, then these programs must also be available
on the new PC. The PLC program must be downloaded to the
corresponding system stations on the new PC.
Note To enable you to create a wide range of different system, the library has
been extended with the addition of new station models. The new
standards regarding circuit diagram design are taken into consideration
in the PLC programs and circuit diagrams. "Old" and "new" standards
differ with regard to the designations of valve coils, pushbuttons and
switches as well as indicator lights.
4.1 The stations models for the configuration of a system are available in
Creating a new MPS® two libraries:
Standard system from • MPS® stations library,
preassembled station • MPS® 500-FMS library.
models
If you want to model a new MPS® Standard system, then use the models
from the MPS® stations library.
Station models for an MPS® Standard system are arranged directly next
to one another.
The alignment and connection of models is effected in a simple way via
specified coupling points on the models. The automatic alignment
ensures that the StationLink sensors of neighbouring stations are also
correctly positioned. The StationLink sensors are optical sensors which
transmit the communication signal.
Note A system can also be configured of just one station, whereby you can
teach all the training contents in COSIMIR® PLC Advanced for which only
a single station is required.
Handling –adjusted
combine your
MPS® Standard
for termination
Distributing –
stations
Testing
Buffer
Distributing – Standard
Distributing – adjusted
for testing
Testing
Processing
Buffer
Separating
Storing – Stock up
Robot
Robot assembly
Sorting
combine your
Storing – Stock up
Robot assembly
stations
Separating
Sorting
Robot
Distributing – Standard
Distributing – adjusted
for testing
Testing
Processing
Buffer
Separating
Storing – Stock up
Robot
Robot assembly
Sorting
Two sequences are available for the storing station: The station can
stock up or take our workpieces. Each sequence is realised via a
separate PLC program. If the station is at the beginning of the material
flow it thus forms the first station of a system – consequently
workpieces are taken out. In this case you will require the variant
Storing Station – Take out. If the storing station forms the end of a
system, then you use the variant Storing Station – Stock up.
The operation of the system with the prepared PLC programs can only
be simulated fault-free if a system is correctly assembled.
Note By clicking onto the picture or title of a model in the help window, the
COSIMIR® PLC Advanced Assistant is displayed. This is where a
functional description and technical documentation regarding the
model are available.
In addition, you can download a few prepared sample systems directly
from the Assistant.
If you do not require the information of the Assistant when starting
COSIMIR® PLC Advanced, deactivate the entry Open Automatically of
the assistant in the Help menu.
8. If the representation of the station is too small, you can change this
using the commands in the View menu. Please note: The Edit Mode
is deactivated if you execute the commands from the View menu.
9. Make sure that the Edit Mode is selected. You can establish this by
the check mark next to the Edit Mode command in the Execute
menu. Now add the testing station as an additional station.
10. All stations are added at the same position in the workspace. Move
the newly added testing station, by highlighting the testing station
and, by holding down the left mouse button, moving the mouse
pointer to the desired position.
11. The two models are next to one another, but are not yet connected.
In order to ensure that the operating and transfer points coincide
during the production run of the system, the station models must be
appropriately aligned and connected.
12. Now align the testing station model with the distributing station
model.
To do so, click onto the lower, grey shaded coupling point of the
testing station. Hold down the left mouse button and drag the
coupling point to the coupling point of the distributing station.
The testing station is now connected to the distributing station.
13. Add the sorting station as the last station. This station is also shown
at the predefined position in the activity window.
14. Click onto the newly added, still highlighted station and move it up
next to the testing station.
15. Connect the sorting station model with the upper free coupling
point of the testing station model.
To do so, click onto the grey shaded coupling point of the sorting
station. Hold down the left mouse button and drag the coupling
point to the free coupling point of the testing station.
The highlighting of the model is cancelled as soon as you click
outside of the station model.
Exit the edit mode as soon as your system is configured. Change to the
view mode to obtain a realistic 3D representation of the system.
Note Once you have created or modified a system, a Save prompt will be
displayed when you close the process model.
If you want to save the changes, answer the prompt with Yes or answer
with No if you want to discard the changes.
4.2 The station models to configure a system are available in two libraries:
Creating an MPS® 500- • MPS® Stations library,
FMS system from • MPS® 500-FMS library.
preassembled station
models If you want to model an MPS® 500-FMS system, then use the station
models from the MPS® 500-FMS library.
S HL RM
Small parts store
Presorting
HH
P H VI
V B
The positioning and alignment of the models is effected simply via the
specified coupling points on the models.
In the case of MPS® 500-FMS systems, the station models are aligned
with the transport system model and connected to it. The connection or
coupling points correspond to the stopper positions of the transport
system. As a result of establishing the connections, the default
communication links used are also simultaneously established.
Note By clicking onto the picture or title of a model in the help window, the
COSIMIR® PLC Advanced Assistant is displayed, where a functional
description and technical documentation regarding the model are
available.
You can also download some prepared sample systems directly from
the Assistant.
If you do not need the information of the Assistant when starting
COSIMIR® PLC Advanced, then deactivate the entry for automatically
opening the Assistant in the Help menu.
3. Select a directory to store the new system. Enter the file name.
Under file type, select COSIMIR® Workcells (*.mod). Then click onto
the Save button.
6. First, insert the transport system model from the MPS® 500-FMS
library by clicking onto Transport System. A preview then displays
the model. Now click onto the Add button.
Alternatively, you can add a model by clicking onto the
corresponding model entry.
The system now consists of the model of the transport system,
which is shown in green as it is still highlighted.
8. Move the transport system model into the centre of the workspace.
To do so, highlight the model via a mouse click. Then drag the
mouse pointer to the desired position by holding the left mouse
button down.
10. All stations are added at the same position in the workspace. Move
the newly added product input station combination. The operating
position for product input is at the bottom left of the transport
system.
11. The two models are next to one another, but are not yet connected.
To ensure that the operating and transfer points coincide during the
production run of the system, the models must be appropriately
aligned and connected.
12. Now align the model for product input with the transport system
model by clicking onto the grey shaded connecting point of the
stations for product input. Hold down the left mouse button and
drag the connecting point onto the connecting point of the transport
system.
The station combination for product input is now connected to the
transport system.
13. Next enter the station combination for the processing sequence by
double clicking onto Processing in the MPS® 500-FMS library. This
station combination is also shown at the predefined position in the
activity window.
14. Connect the newly added, still highlighted model to the lower
middle connecting point of the transport system model by
clicking onto the grey shaded coupling point of the highlighted
processing model. By holding down the left mouse button drag the
coupling point to the lower, middle coupling point of the transport
system model.
15. Finally, add the model for product output. Again, this model is
shown at the predefined position in the activity window.
16. Move the newly added product output station combination. The
operating position for product output is at the top left of the
transport system.
17. Connect the product output model to the top left connecting point of
the transport system.
The highlighting of the model is cancelled as soon as you click
outside of the station model.
18. The system is created. The default communication links used have
been automatically established during modelling of the system.
19. Now exit the Edit Mode and change to the View Mode to obtain a
realistic 3D representation of the system.
3. Close the Model Libraries window. This will give you more space for
the system representation.
The system is created and correctly connected. You can now simulate
system product straight away.
Note If you have newly created or modified the process model of a system, a
save prompt will be displayed when you close the process model.
If you want to save the changes, then answer the prompt with Yes, or
answer the prompt with No, if you want to discard the changes.
4.3 You can modify the model of a system and for example add further
Modifying an existing stations. How you proceed for this and what you need to observe
system depends on what communication links are to be used within the system.
• In MPS® Standard systems, optical sensors are used as standard to
effect communication.
If the stations of an MPS® Standard system are correctly positioned
and connected, using the connecting points, then the
communication links are automatically established by means of this
process.
• If you change an MPS® Standard system for which you have realised
multi-bit communication via I/O connection, then the
communication links must be re-established.
If you only use the default communication links prepared and want
to establish these, then activate the command Create
Communication Links in the Execute menu.
All other communication links are to be established in the Manual
Operation window.
• Multi-bit communication via I/O connection is available as standard
in MPS® 500-FMS systems.
When modelling, or also modifying such a system, the
communication links are set up automatically.
• However, if you modify an MPS® 500-FMS system where you are not
using the prepared default communication links, you need to set up
the communication links yourself after modelling. User-defined
communication links are set-up in the Manual Operation window.
Note You will need the Object Properties function if you use a station in a
system several times and wish to identify the individual stations. You
identify a station by its name.
Example: If you are using the buffer station twice in your system, the
name of the station added first is Buffer and the name of the
subsequently added buffer station is Buffer_1.
7. If you now wish to add another station to your system, change to the
top view representation in View by activating the Standard/Top
View command in the View menu.
9. Make sure that edit mode is selected. You can establish this by the
check mark next to the command Edit Mode in the Execute menu.
10. Now open the model libraries by activating the Model Libraries
command in the Execute menu.
11. In the case of the sample system, this is an MPS® Standard system.
For modifications to the system, you will need the stations of the
MPS® Stations library. Open the library by clicking onto the +
symbol in front of MPS® Stations library.
12. Carry out your modifications to the system. If you want to expand
the system by adding assembly functions, then add for example the
Pick & Place and Fluidic Muscle Press stations between the sorting
and testing stations.
13. To add the desired stations, highlight the sorting station and move
it up.
14. Now insert the Pick & Place station by double clicking the library
entry Pick & Place Station.
15. Position the added station next to the testing station by clicking
onto the highlighted Pick & Place station and move the mouse
pointer to the desired position by holding down the left mouse
button.
16. Connect the new Pick & Place station to the testing station by
clicking onto the bottom, grey shaded coupling point of the Pick &
Place station. Drag the coupling point to the coupling point of the
testing station by holding down the left mouse button.
The testing and Pick & Place stations are now interconnected.
17. Use the same method to add the Fluidic Muscle Press station.
Connect this station to the Pick & Place station.
18. Finally, connect the sorting station to the Fluidic Muscle Press
station.
To do so, highlight the sorting station. Then drag the coupling point
of this station to the unoccupied coupling point of the Fluidic
Muscle Press station whilst holding the left mouse button.
19. The changes to the system are completed. The communication links,
realised via the optical StationLink sensors, are automatically set up
via the correct positioning and connection of the stations.
Close the library and change to the view mode to obtain a realistic
3D display of the system.
20. Deactivate edit mode in the Execute menu by clicking onto the Edit
Mode command. The check mark next to Edit Mode disappears.
21. To obtain a perspective view of the 3D model, select for example the
Standard/Default Settings command in the View menu. By using
the commands under View you can move, rotate or zoom to obtain
an appropriate view of your system.
22. Save the modified status of the system by activating Save in the File
menu if you want to keep the current file name. Select the Save as
command if you want to save the system under a new name.
Note In the same way as you can expand a system by adding new stations
you can also remove existing stations of a system, whereby you proceed
as follows: Highlight the respective station. Open the context-sensitive
menu via the right mouse button, where you activate the Remove
command. The station highlighted is removed.
MPS® Standard systems • In an MPS® Standard systems, communication takes place in the
form of 1-bit connection via optical sensors as standard. As soon as
the stations of a system are correctly positioned and connected with
the help of the coupling points, the optical sensors are also correctly
positioned to transmit communication signals. The prerequisites for
error-free transmission of communication information are therefore
in place.
• The absolute addresses of the PLC inputs and outputs of a station
connected to the optical sensors can be found in the allocation list
of the sample PLC program. You will find the technical
documentation and information regarding the sample PLC program
in the COSIMIR® PLC Advanced Assistant.
To open the COSIMIR® PLC Advanced Assistant, activate the
Examples and Models of COSIMIR® PLC Advanced command in the
Help menu. Open the chapter COSIMIR® PLC Advanced in the
Contents register.
• If you have expanded the 1-bit communication in a MPS® Standard
system to multi-bit communication via I/O connection, then you will
need to create the additionally required communication links in the
virtual system.
Only if these communication links have been set up, can the
information exchange between the system stations take place
during simulation.
• Different PLC inputs and outputs are available for the transmission
of communication information.
To enable you to work with a networked system promptly, the
communication links between the stations are already prepared.
You can establish these at the click of a button, whereby specific
PLC outputs of a station are connected to specific PLC inputs of
neighbouring stations. Conversely, a number of PLC inputs of a
station are of course also connected with PLC outputs of
neighbouring stations.
• You can see all I/O communication links set up for an MPS® system
in the Manual Operation window.
Control I4 Q6 I4 Q6 I4 Q6
console I5 Q7 I5 Q7 I5 Q7
Q4 I6 Q4 I6 Q4 I6
Q5 I7 Q5 I7 Q5 I7
The tables below list the allocation of the symbolic PLC addresses used
for communication to the absolute PLC addresses.
IP_N_FO Q0.7
Allocation of symbolic PLC addresses to the absolute PLC addresses for a number of MPS® Standard
stations
The prepared default communication links for a small MPS® 500-FMS system; only working position 1 of the
transport system is allocated
The tables show the allocation of the symbolic PLC addresses used for
communication to the absolute PLC addresses.
IP_N_FO Q0.7
Allocation of symbolic PLC addresses to the absolute PLC addresses for a number of MPS® 500-FMS stations
Note The transport system station has the communication interface shown
for each of the six working positions. The name of the communication
variable includes a reference to the working position for the purpose of
differentiation. The working position is identical to the stopper position.
The communication variable for working position 2, i.e. the processing
working position, starts with ST2_. These variables do of course have a
different absolute address than the variable starting with ST1_.
You will find the complete list of the communication variables of the
transport system station in COSIMIR® PLC Advanced Assistant.
Display of communication Communication links are created and displayed in the Manual
links Operation window.
The righthand part of the window shows the process activities. These
are the variables which adjust the simulation of the process model. The
user cannot change the value of these variables. Examples of process
activities are sensor signals or also the values of communication
outputs.
The signal flow of a communication links runs from right to left. You can
see this by the orientation of the arrow at the end of the links.
1. Make sure that the desired MPS® is loaded. The example selected
shows an MPS® 500-FMS system. This system consists of a
transport system, the distributing and testing stations in the form of
product input and the handling and sorting stations in the form of
product output.
7. You can now simulate the running of the prepared PLC programs.
1. Make sure that the desired MPS® system is loaded. The selected
example shows an MPS® 500-FMS system. The system consist of a
transport system, the distributing and testing stations in the form of
product input and the handling and sorting stations as product
output.
3. All default communication links are now deleted. You can establish
this in the Manual Operation window in the I/O Connections
section. Connections are displayed neither between the
communication inputs/outputs of the distributing and testing
stations nor between the communication input/outputs of the
testing and transport system stations. The same applies for the
product output and transport system stations.
11. Proceed in the same way if you require further communication links
between the stations of your system.
4. Click onto the entry, whose connection you want to delete. In this
exampIe, this is the I4 Communication entry of the testing station.
If you want to see the communication output with which
14 Communication is connected, then scroll down in the righthand
section of the window until the connection is fully displayed.
4.5 The production run of the system can be simulated as soon as a system
Simulating a system is modelled and the necessary communication links are set up.
Note The user can disconnect the connection between station models and
PLC selectively in order to manually control individual process
components.
The file name and path data of the loaded system are shown in the
header line.
The status bar informs you regarding the operating status of the
system:
Note In COSIMIR® PLC Advanced the two simulation modes Cycle and
Running are identical.
1. Make sure that the system is in the initial position by executing the
Reset Workcell command in the Execute menu.
2. Activate the Start command in the Execute menu.
The simulation is active. You can identify the simulation mode in the
status line via the Running entry.
Alternatively you can also activate simulation via the Start Cycle
menu entry or via the Stopped button in the status bar.
4.6 If system simulation is active, you can operate each station controlled
Operating and monitoring via the sample PLC program using the pushbuttons and switches of the
a system corresponding control console. You can identify the status of simulation
on the status bar.
Process module
Control console of MPS Standard station Control console of transport system station
I4
I5
Start Stop
Q4
Reset Auto/Man
Q5
GND
Q1 Q2
I/O
Blue
Black
Red
Metal
Blue
Black
Red
Metal
1. Make sure that the system is in the initial position and that there are
no workpiece on the stations. You realise this by activating the
Reset Workcell command in the Execute menu.
4. Carry out the reset function for each station by clicking onto the
Reset button. We recommend that you carry out the resetting of the
individual stations against the material flow.
Note Not every workpiece is suitable for every station. If you have selected a
workpiece which cannot be processed by a station, this workpiece
cannot not be generated for the station.
8. Start the sequence of each station by clicking onto the Start button.
This starts the automatic mode of the station. We recommend that
you start the stations in the sequence in which they are arranged in
the material flow.
9. With the key actuator you can choose between continuous cycle
(switch position vertical) and individual cycle (switch position
horizontal) for the sequence of a station.
10. You can interrupt the sequence of a station at any time by pressing
the STOP button. If you want to restart the station, you need to carry
out the Reset function beforehand.
If a station is controlled via a PLC program you have created, then you
will know how the running and operation of the station are defined.
If a station is not controlled via a PLC program, you can selectively
trigger the process actuators manually. You will need the manual
operation window functions for this.
Note Slides filled with workpieces, which result in the production process
stopping, can be emptied via appropriate commands in the manual
operation window.
1. Make sure that the system is in the initial position and that there are
no workpieces on the stations. This applies in particular to the
pallets of the transport system station, the storage slots of the
automated warehouse station and the slides of the sorting station.
Remove all workpieces by activating the Reset Workcell command
in the Execute menu.
6. Carry out the reset function for the stations mentioned by clicking
onto the Reset button.
10. The illuminated Start button on the MPS® stations indicates that
the corresponding stations are in the initial position and that the
start precondition is fulfilled.
11. As soon as you have filled the magazine of the distributing station
with workpieces, i.e. with basic cylinder bodies, the start
precondition for this station is also fulfilled. The Start button is
illuminated.
12. Fill the magazine by clicking onto the desired workpiece on the
workpiece table. The selected workpiece, a red basic cylinder body,
is shown depressed.
Then click onto the symbolic workpiece on the distributing station.
With each mouse click the magazine is filled with the workpiece
selected.
13. Start the sequence of each station by clicking onto the Start button.
14. With the AUTO/MAN key actuator you can choose between
continuous cycle (switching position vertical) and individual cycle
(switching position horizontal) for the sequence of a station.
15. You can interrupt the sequence of a station at any time by pressing
the STOP button. If you want to restart the station, you need to carry
out the Reset function beforehand.
Note regarding the The automated warehouse station only participates actively in the
automated warehouse production process if product output for the process is not or is no
station longer available for the process.
Note regarding the quality The quality assurance station identifies the housing for a measuring
assurance station instrument as a reject part. The station passes on this information to the
transport system station and the transport system station passes on the
information to the robot assembly station. The robot then rejects the
transferred reject part.
Note • If a station is controlled via a PLC program you have created, you will
know how the running and operation of the station is defined.
• If the station is not controlled via a PLC, you selectively trigger the
process actuators manually. You will need the functions of the
Manual Operation window for this.
• Slides filled with workpieces and which result in the production
process stopping, can be emptied using appropriate commands in
the Manual Operation window.
• LEDs on the sensors and valves indicate the electrical status of the
process components.
• The LEDs on the inputs/outputs on the control console, provided for
the I/O connection, indicate the status of the communication
signals.
• If air is applied at a cylinder connection, the connection is
highlighted in blue.
• The pneumatic tubing itself is not shown.
• In the windows Inputs and Outputs you can identify the status of the
PLC signals for the station selected.
• The Manual Operation window provides you with an overview of all
process statuses and process activities of the system and also
displays all the communication links.
• The designation of a component is shown by clicking onto the
connection or the LED of a process component. This designation is
identical to the designation in the circuit diagram.
• One exception is the designations of the supply ports. These form
part of the valves which supply the supply port with air.
Note You can also display additional information regarding the sensors. The
settings for this are effected in model explorer.
• Activate the command Model Explorer in the Execute menu.
• A tree structure is displayed.
• Click onto the top entry. In the case of an MPS® 500-FMS system,
the entry is MPS® 500.
• Now activate the context-sensitive menu via the right mouse button
and select the Properties command.
• The window Workcell Properties is displayed.
• Activate the Sensor Simulation register.
• In the Visualisation section click onto the two check boxes for the
entries Show Measuring Range and Show Measured Value(s). Both
boxes are now shown with a tick.
4.7 You can freely adjust the perspective view of a modeled system. With a
Changing the view of a few central commands you can rotate, move, enlarge or minimize the
system representation of the process model.
Reference point
Turn Angle
Z
You can also activate the Move command by holding down the shift key
and then pressing the left mouse button.
You can also activate the Rotate command by holding down the Ctrl key
and then pressing the left mouse button.
You can also activate the Zoom command by holding down the key
combination Shift+Ctrl and then pressing the left mouse button.
Activate the Zoom-Out command in the View menu. The picture is now
reduced to 80%.
4.8 The Inputs and Outputs windows show which signals are applied at the
The Inputs and Outputs inputs and outputs of the PLC for the selected station. 0 signals are
windows shown 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>.
2. Select the station whose PLC inputs you wish to observe. To do so,
click onto the Controller Selection in the Execute menu. Select the
desired PLC in the Master column via a mouse click.
Note The Controller Selection window displays all the stations of the
modelled system which have their own internal controller. The
controllers are switched to active by default. If system simulation is
started, for example via the Start command in the Execute menu, then
the PLC programs of the active controllers are started in sequence4. If
system simulation is stopped, the execution of the PLC programs in the
active controllers is also stopped. The status as to whether or not a PLC
is operating is shown in the Start/Stop column.
The status of PLC inputs/outputs is displayed in the Inputs/Outputs
window only for the controller selected as Master. Also, PLC programs
can be loaded to the selected internal controller. To do so, use for
example the Open File command in the File menu.
So that you know which process signal it is, the signal names include
the relevant designations from the circuit diagrams.
Example: STATION_1B2: The PLC input which is connected to sensor
1B2.
2. Select the stations whose PLC you wish to observe by clicking onto
the Controller Selection command in the Execute menu. Select the
desired PLC in the Master column.
Note The Controller Selection window displays all the stations of the
modelled system which have their own internal controller. The
controllers are switched as active by default. If simulation of the system
is started, for example via the Start command in the Execute menu, the
PLC programs of the active controllers are started in sequence. If system
simulation is stopped, then the execution of the PLC programs is also
stopped in the active controllers. The status as to whether or not a PLC
is operating is displayed in the Start/Stop column.
The status of PLC inputs/outputs is displayed in the Inputs/Outputs
window only for the controller selected as Master. Also, PLC programs
can be loaded to the selected controller. To do so, use for example the
Open File command in the File menu.
So that you know which process signal it is the signal names include the
relevant designation from the circuit diagrams.
Example: STATION_1Y1: The PLC output which is connected to valve coil
1Y1.
You can monitor all process activities in the righthand section of the
window.
The process statuses include status of sensors, valve coils and
communication outputs. Here, 1 signals are indicated by a green
illuminated LED.
Process statuses are variables that are set and correspondingly
displayed by the process model simulation. The user cannot change the
value of these variables.
The status of signals is also shown in the Value column. If the signal is
forced, the value is shown in angled brackets.
You can show or hide the display of the Value column. You will find the
relevant command in the context-sensitive menu via the right mouse
button.
The signal flow of a communication link runs from right to left. You can
see this by the orientation of the arrows at the connection ends.
Additional information I/O connections are connections between the inputs and outputs of the
regarding the I/O system.
connections
Differentiation should be made between
• PLC inputs and outputs on the controller side,
• Process inputs and outputs on the process side.
PLC outputs, for example the signal for a valve coil, are input signals for
the process.
Conversely the process generates output signals, for example sensor
signals, which are then connected to a PLC input.
Symbol Meaning
Important You may only delete those I/O connections, which you have created
yourself as communication links. Otherwise it may no longer be
possible to simulate the system correctly.
1. Make sure that the desired system is loaded. The example selected
shows an MPS Standard system, which is made up of the
distributing, testing and sorting stations.
Note You can show or hide the middle section of the Manual Operation
window headed I/O Connections as required. To do so, activate or
deactivate the Show I/O Connections command in the context-sensitive
menu via the right mouse button.
Note You can of course also disconnect the controller from just one station.
To do so, highlight the required station in the Process Activity section of
the Manual Operation window. Then open the context-sensitive menu
via the right mouse button and select the Disconnect Selected
Controllers command.
7. To control the system via the PLC programs in the controllers again,
move the mouse pointer into the left section of the Manual
Operation window to the Process Activities. Open the context-
sensitive menu via the right mouse button and select the Restore
I/O Connections command.
Notes The execution of the Reset Workcell command in the Edit menu also
causes the inputs/outputs of the system to be reconnected to the
inputs/outputs of the controllers.
The stops merely influence the simulation of the system, the PLC
programs for the control of the system remain unaffected. If a stop is
applied to a signal, the system simulation stops if the signal value
changes. The changed signal value is transmitted to the system as soon
as simulation is restarted.
8. If you want to delete the stop, click onto the line with the stop point
with the right mouse button. Open the context-sensitive menu via
the right mouse button and select the command Stop at Value
Change. This command is realised in the form of a toggle function.
The stop is removed. Alternatively you can also select the Delete All
Stops command.
Note that you can also set stop at the signals in the Process Status
section of the window.
changes its status. If you also want to take into consideration and
monitor communication signal during the step by step operation, then
you need to set the stops at the corresponding signals in the window
section Process Activity and Process Status.
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.
9. Open the context-sensitive menu via the right mouse button if you
want to remove the stops again. Select the Delete All Stops entry,
doing so for both window sections.
A sample PLC program for S7-300 is available for each station. When
you load a station from the library, the sample PLC program is
automatically loaded to the internal PLC of the respective station. Once
simulation of the system is started the internal PLC executes the S
program. You can of course also download a different S7 program to the
internal PLC of a station. If doing so, you need to keep in mind the
following: Only complete project files with the file extension S7P can be
loaded. The projects must have been created with the SIMATIC Manager
and conform to the Siemens MC7 code at the binary level. This is the
case with all STEP-7 programs created in LDR, FCH or STL. With STEP7
programs created in GRAPH, correct execution via the S7 simulator is
not guaranteed.
1. Load the desired MPS system. The sample selected displays an MPS
Standard system. The system is made up of the distributing, testing
and sorting stations.
Note If you have modified the PLC program for a station in the corresponding
internal PLC, the modified PLC program will of course be executed once
simulation is started.
3. Select the station whose PLC program you want to modify. The PLC
program is to be executed by the internal PLC.
To do so, activate the Controller Selection command in the Execute
menu. In the Controller Selection window click on to the required
station in the Master column.
4. Select the Open command in the File menu to open the Open File
window.
Note Another option is also available for loading PLC programs to the internal
PLC of station.
4. The just loaded PLC program for each internal PLC is shown in a
clearly set out tree structure.
Click onto the + symbol in front of the station whose PLC program
you want to change. In the exampIe the testing station has been
selected. Highlight the Program entry.
5. Open the context-sensitive menu via the right mouse button and
select the Load command.
The required PLC program is loaded. You can now simulate the
operation of the system.
3. A clearly set out tree structure shows the just loaded PLC program
for each internal PLC.
4. Click onto the + symbol to display the name and structure of the PLC
program.
The PLC program can consist of the following modules: Organisation
modules, data modules, functions and system functions.
5. Click onto the + symbol again to display the modules of the PLC
programs.
You can view the contents of the module by double clicking onto a
module.
This is how the sample PLC programs are filed on the computer
1. Select the Open command in the File menu. The Open File window is
now displayed.
2. Select S7 Project (*.S7P) under file type.
All the files of this format available in the active directory are
displayed.
3. Navigate into the directory in which you have installed the Software
package COSIMIR® PLC Advanced software package. From there
change to the directory \COSIMIR® PLC
Advanced\bin\FD_PLC_ADV\S7 where four subdirectories are
shown.
– The directory MPSC_V22 contains the S7 project mpsc_v22.s7p,
where you will find the sample PLC programs for all MPS
Standard stations.
– The directory FMS50__1 contains the sample PLC programs for
the transport system of MPS 500-FMS systems.
– The directory 313C__1 contains the sample PLC programs for the
individual stations of MPS 500-FMS systems.
– The directory Store contains the sample PLC programs for the
automated warehouse station.
The program name provides information about the PLC program and the
station model to which it belongs:
• The initial digit corresponds to the station number.
• The two letters after the first digit indicate the station:
VE: Distributing station
PR: Testing station
BE: Processing station
HA: Handling station
PU: Buffer station
MO: Assembly station
SO: Sorting station
PP: Pick&Place station
FM: Fluidic Muscle Press station
TR: Separating station
LA: Storage station
• The letters starting with underscore indicate the programming
language of the PLC program:
AS: The programming language GRAPH,
KFA: The programming languages LDR, FCH and STL,
Note that the internal S7 PLC can only reliably execute LDR, FCH or STL
programs.
Note You must never modify the sample PLC programs shown here because
these are the standard default programs required for the simulation of
an MPS system.
If you want to make changes to the PLC programs, then install these a
second time using the specially provided installation program
SetupSamples.exe.
4.11 S7-PLCSIM is a soft PLC, which executes the PLC programs created in
Controlling a system STEP 7. A wide range of different testing and diagnostic functions for
station using the external fault finding in the PLC program are available within STEP 7. These
Soft PLC S7-PLCSIM testing and diagnostic functions include for example the status display
of variables or the online display of the PLC program. You can use these
functions if you create the PLC program for a station of a system in
STEP-7 and then test the PLC program in conjunction with the
simulation of the system.
The exchange of PLC input/output signals between the system and the
soft PLC S7-PLCSIM is effected via the EzOPC program. EzOPC must be
installed on your computer. If this is not the case, then carry out the
installation from the CD-ROM COSIMIR® PLC Advanced now.
Once successfully installed, EzOPC is automatically invoked by
COSIMIR® PLC Advanced as soon as simulation of the system starts. The
prerequisite for starting EzOPC is of course that at least one station of
the system is controlled via an external PLC.
This is how you control a station of the virtual system using S7-
PLCSIM
7. Make the necessary setting for the desired station, i.e. that this is to
be controlled via an external PLC by activating the Switch external
PLC ↔ internal PLC command in the Execute menu.
9. Highlight the desired station via mouse click. Activate the context-
sensitive menu via the right mouse button and select the Switch
command.
Alternatively changeover the controller by double clicking the
desired station.
10. For the selected station OPC server is now entered in the Type
column. The name FestoDidactic.EzOPC.1 is now displayed under
program name/OPC server. This entry means the process signals for
the selected station are exchanged via an OPC server named
FestoDidactic.EzOPC.1.
14. Click onto EzOPC in the start bar. The EzOPC – 4.9.6 window is now
displayed, where you configure the communication between
COSIMIR® PLC Advanced and S7-PLCSIM.
The interface EasyPort D16 is crossed out. This signals that no
communication link exists between EasyPort and EzOPC, nor is a
communication link set up to S7-PLCSIM.
23. Start S7-PLCSIM by clicking onto the check box next to RUN in the
CPU window. The LED for RUN should now start flashing.
25. Make sure that the PLC inputs and outputs for the right station are
displayed by activating the Controller Selection command in the
Execute menu. Select the controller for the desired station in the
master column. For the example this should be the distributing
station.
26. If errors still exist in the PLC program, then the online representation
in STEP 7 provides excellent support during fault finding. To do so,
call up the program module in which you suspect the fault. Activate
the Monitor command in the Test menu. You can now monitor which
PLC program sections are executed or not in parallel with the
simulation of the process.
4.12 If you are creating and testing your own PLC programs we recommend
Controlling a station of that you load the programs to an external PLC and execute them from
the system using an there.
external PLC
If you are programming in STEP 7, you can use the soft PLC S7-PLCSIM
as PLC, in which case you will not require any additional hardware
components.
You can however also use any other control and programming system,
in which case you load the PLC program to your hardware PLC. The PLC
program is to control a selected station of your virtual system. The
EasyPort
PLC
You can however also select another configuration and install the two
software packages on one PC. Your PC needs to be equipped with two
serial interfaces if you want to use the testing and diagnostic functions
of the programming system during simulation of the virtual system.
The EzOPC program The EzOPC program organises the exchange of PLC input/output signals
between the virtual system simulation and the external PLC. EzOPC
does not access the signals of the external PLC directly but via the
EasyPort interface.
EzOPC must be installed on your computer. If this is not the case you
need to carry out the installation from the CD-ROM COSIMIR® PLC
Advanced now. Once successfully installed, EzOPC is automatically
invoked by COSIMIR® PLC Advanced as soon as simulation of the
system starts. Prerequisite for starting EzOPC is of course that at least
one station of the system is controlled via an external PLC.
Configuration of EzOPC for data exchange with an external PLC via EasyPort
1. Load the desired PLC program to the external PLC. The external PLC
is in the STOP operating status.
2. Connect the PC with COSIMIR® PLC Advanced to the external PLC via
the EasyPort interface.
– The data cable Pt. No. 162 305 connects the serial interface of
the PC to the serial interface RS232 of EasyPort.
– 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.
– Select the following setting for the DIP switches under Mode on
EasyPort:
1 ON (bottom), 2 OFF, 3 OFF.
Process model
1 2 3
ON
S7 EduTrainer EasyPort
RING IN OUT MODE RS232 - 24V +
CPU313C-2 DP CP 343-2
SF SF
BF 0 0 PWR
DC5V 1 1 APF
FRCE 2 2 CER
RUN 3 3 AUP
STOP 4 4 CM
PUSH
5 5 EasyPort D16
6 6 B
RUN
7 7 20+
STOP
MRES ∆ ∆ 10+
IN OUT SET
A STATUS SHORT
∆ ∆
9
0 0 8
1 1 7 INPUT
2 2 6 OUTPUT
3 3 5 0 7 8 15
4 4 4
5 5 3
6 6 2
7 7 1
0 PORT 1 PORT 2
B
3
1
Note The two sockets marked EMERGENCY-STOP must be bridged so that the
output modules of the PLC receive the voltage supply.
Prozessmodell
1 2 3
ON
EasyPort
RING IN OUT MODE RS232 - 24V +
EasyPort D16
STATUS SHORT
INPUT
OUTPUT
0 7 8 15
PORT 1 PORT 2
XMA2 XMG1
SPS-Board
7. Highlight the required station via a mouse click. Activate the context
sensitive menu via the right mouse button and select the Switch
command.
Alternatively changeover the controller by clicking onto the required
station.
8. OPC Server is entered for the selected station in the Type column.
FestoDidactic.EzOPC.1 is shown under Program name/OPC Server.
This means that the process signals for the selected station are
exchanged via an OPC server named FestoDidactic.EzOPC.1.
11. Start the system simulation by activating Start in the Execute menu.
With the starting of simulation, the EzOPC program is automatically
invoked. You can establish this by the EzOPC entry in the start bar.
If EzOPC is not invoked, check whether the program is installed.
Carry out the installation now.
If EzOPC is installed but not invoked, stop and restart simulation of
the system again. You will see Cycle or Running displayed in the
status bar of the system simulation.
12. Click onto EzOPC in the start bar to open the EzOPC–4.9.6 window.
Here you configure the communication between H COSIMIR® PLC
Advanced and EasyPort.
The EasyPort D16 interface is crossed out, which signals that there
is no communication link between EasyPort and Ez0OPC; neither is
there a communication link set up to S7-PLCSIM.
13. Effect the settings for the serial interface by activating serial port
settings for EasyPort in the Configuration menu.
14. The serial port settings for Easy Port window opens..
Under COM Port enter the serial interface of your PC to which
EasyPort is connected. Confirm the setting with OK.
Note In rare cases the EzOPC program may not have copied the settings
correctly. If so, close the EzOPC window and restart simulation. This
also restarts EzOPC. The EzOPC settings are now correctly copied.
25. Operate the system and in particular observe the behaviour of the
station for which you have created the PLC program, whereby it may
be helpful to observe the statuses of the PLC inputs and outputs of
the relevant station. Open the inputs and outputs window by
activating the Show Inputs/Show Outputs command under the
Inputs/Outputs entry in the Extras menu. .
26. Make sure that the PLC inputs and outputs for the right station are
displayed. Activate the Controller Selection command in the
Execute menu and select the controller for the desired station.
4.13 Use the Fault Setting window to set specific faults in the functional
Setting faults in a system sequence of a system. Use the internal S7 PLC and the sample PLC
programs provided to control the system. This ensures that any
potential process malfunction is caused solely by the process
components. The PLC programs operate error-free.
The setting of faults is permissible for authorised persons only and the
dialog for the setting of faults is therefore password protected. The
default setting for the password is didactic. This password can be
changed at any time.
+ symbol of a station. To hide the entries again double click the minus
symbol.
The following data is required if you want to create a fault in the case of
one of the listed process components:
• Type of fault,
• Start of malfunction,
• Duration of malfunction.
Various faults can occur in the case of some components. You can select
these in a selection list.
The error statuses are effected in the simulation of the modelled system
as soon as the fault simulation is active.
Note Default malfunction however only becomes active if the fault simulation
mode is activated.
6. Now set a malfunction – for example for the PLC input 1B1.
Double click the appropriate field in the Type column. A selection list
is displayed. Open this list and select the type of fault, for example
cable break.
The fault is to become active at the start of simulation and remain
active until the fault is removed from the fault setting. No entries are
therefore required in the Begin column.
The duration of the fault is arbitrary. No entries are therefore
required in the Duration column.
This is how you start simulation of the system with set faults
Example The MPS system viewed consists of the distributing, testing and sorting
stations. The sequence of the system stops once a workpiece is ejected
at the distributing station. The next step - moving the swivel arm into
the magazine position - is not executed.
By observing and evaluating the system, you realise that voltage is
applied at sensor 1B1 of the distributing station, but not at the
corresponding PLC input. You therefore conclude a cable break at the
PLC input 1B1.
5. Double click no fault in the line PLC input 1B1 and select cable
break from the selection list.
The button is illuminated in yellow.
If the fault has been identified correctly, the distributing station
sequence will be executed error-free in the next simulation cycle.
Note • If you have correctly identified and entered the fault, the sequence
of the system will be executed error-free in the next simulation cycle.
• If the cause of the fault has not been identified correctly, the fault
will continue to exist.
• If you have erroneously identified and entered the cause of the fault
as a mechanically misaligned sensor, you have created an additional
fault in the process. The fault is active as of the next simulation
cycle.
4.15 Each action in the Fault Localisation window is recorded in a log file.
Logging error elimination Authorised persons have the option of viewing the log file.
The log file contains a list of activities carried out in the fault localisation
window. The entries contain the following data
• Date
• Time
1. Open the fault log window by activating the Fault Log entry in the
Execute menu.
2. The dialog box for the password entry is now displayed.
Enter the password. The preset default password is still valid,
provided that you have not changed this since installing COSIMIR®
PLC Advanced.
Enter didactic under password.
Note that the password is case sensitive.
Confirm your entry with OK.
Note If you want to delete the fault log, activate the context-sensitive menu
via the right mouse button and select the appropriate command.
5.1 COSIMIR® PLC Advanced provides process models for different, complex
Training contents and sections of production systems.
training aims
Main training aims The general training aims of COSIMIR® PLC Advanced are to achieve the
following skills
• To design and construct PLC controlled systems in the form of
distributed systems,
• To specify, design and test communication between the intelligent
stations of a distributed system,
• To create, modify and test the PLC programs for the individual
stations of a distributed system or complete system,
• To carry out systematic fault finding as part of servicing and
maintenance of distributed systems.
This training aim deals with all the topics which can be addressed by
means of simulated processes of distributed systems. The main focus of
training is aimed at a methodical procedure.
These include:
• Vocational training
– Mechatronic engineers
– Electronics engineers, for example specialising in automation
technology
– Plant electronics engineers
– Industrial mechanics
• Specialist qualification in the metal and electrical engineering field
• Training at technical colleges and universities
5.3 The following prior knowledge is required for training and working with
Prior knowledge COSIMIR® PLC Advanced:
• Basic knowledge of control technology: Structure of an automated
system
• Basic knowledge of PLC technology: Design and mode of operation
of a PLC
• Basic knowledge of PLC programming and handling of a PLC
programming tool such as the programming system SIMATIC STEP 7
• Basic knowledge of pneumatic control technology: Drives, control
elements
• Basic knowledge of sensor technology: Limit switches, contactlessly
operating proximity sensors
• Basic knowledge of design, wiring and tubing up of
electropneumatic systems.
• Basic knowledge of electrotechnology: Electrical variables, the
correlation and calculation thereof, DC and AC current, electrical
measuring techniques
• Basic knowledge of how to read and interpret circuit diagrams
• Skills in dealing with and operating Windows programs
The tables only lists those training aims which form part of COSIMIR®
PLC Advanced training.
Mechatronics Training area 9: • Describing the information structure of a system with the
engineer Examining the help of circuit diagrams and technical documentation.
information flow in
• Analysing signals and establishing possible error
complex mechatronic
sources.
systems
• Measuring and detecting signal faults in bus systems.
Mechatronics Training area 4: • Fault finding on simple modules with the help of
engineer Examining the energy measuring technology.
and information flow in
electrical, pneumatic
and hydraulic modules
• Documentating faults.
5.6 COSIMIR® PLC Advanced can be used in many different ways for
Training scenarios for vocational and further training. Here are a few examples:
COSIMIR® PLC Advanced
• COSIMIR® PLC Advanced in the form of an introduction for the
purpose of motivation, preparation and as a knowledge database for
actual MPS systems:
The systematic procedure you use and the knowledge you acquire can
be used in any way you choose and of course also on actual systems.
6.1 The following training aims can be taught with the help of COSIMIR® PLC
Training aims Advanced:
• Familiarisation with and understanding of the design and mode of
operation of a distributed system.
• Familiarisation with typical components for the realisation of
automated systems: Sensors and limit switches, pneumatic valves,
pneumatic linear and rotary drives, electrical DC motors,
programmable logic controllers.
• Modelling distributed systems from intelligent stations.
• Operating and observing distributed systems.
• Networking the stations of a distributed system.
• Familiarisation with different production processes.
• Evaluating technical documentation.
• Researching information.
• Recognising the advantage of a simulated system for industrial
operation.
6.3
Example: Configuration of
a distributed system from
MPS® Standard stations
and simulating production
7. Now check which station you need for the required system and how
the system is to be configured.
Result Your investigation shows that you will need the Pick & Place and Fluidic
Muscle press stations for the assembly process. In addition you will
also need the handling station – adjusted for successor station and the
sorting station. The stations are placed directly next to one another and
are coupled via optical sensors.
12. The two models are positioned next to one another but are not yet
connected. To ensure that working and transfer positions coincide
during the production run of the system, both station models must
be correspondingly aligned and connected.
18. The system is now configured. Change into the view mode to obtain
a realistic 3D representation of the system.
Deactivate the Edit Mode command in the Execute menu by clicking
onto the Edit Mode command. The check mark next to the Edit
Mode entry is removed.
23. Each station has an internal PLC. The supplied sample PLC program
is executed with the start of virtual system simulation.
The stations can now be operated using the keys and switches of
the corresponding control console. The sequence of operation is
defined in the PLC program.
24. Once simulation is started, the illuminated reset button requests the
reset function for all stations. The system is moved into the initial
position via the reset function.
Result • Initial position for the handling station: Linear axis in "predecessor
station" position (1B2=1) and lifting cylinder retracted (gripper up)
and gripper open.
• Initial position for the Pick & Place station: Feed separator advanced
and conveyor motor off. Mini slide up and mini slide retracted and
vacuum off.
• Initial position for the Fluidic Muscle Press station: Linear drive
retracted and rotary drive in pick-up position ("predecessor station
position") and pressb up.
26. Execute the reset function for each station by clicking the reset
button. We recommend that you carry out the reset of the individual
stations against the material flow.
In the case of this system, this means: Execute the reset mode of the
sorting station, then the reset mode of the Fluidic Muscle press
station, followed by that of the Pick & Place station and finally the
reset mode of the handling station.
29. Make sure that the workpieces necessary for the production process
of the system are available:
– One workpiece housing at the transfer position of the handling
station,
– At least one workpiece insert on the slide of the Pick & Place
station.
33. With the key actuator you can select either continuous cycle (switch
position vertical) or individual cycle (switch position horizontal) for a
station sequence.
34. The sequence of a station can be interrupted at any time by pressing
the stop button. If you want to restart the station, you need to
execute the reset function first.
The PLC programs are created such that they can be used for stand
alone operation of the stations. At the same time, these PLC programs
also support working with the stations in a network whereby minimal
information about process inputs/outputs is exchanged between the
stations.
Note • In the case of the distributing station only the StationLink receiver is
mounted.
• In the case of the sorting station, only the StationLink emitter is
mounted.
7.2 Proceed step by step to analyse the networking and information flow in
Methods a system. Each step deals with an important aspect of communication.
7.4
Example: Analysing
information flow in a
distributed MPS®
Standard system
6. Use the technical documentation for the two stations for information
as to how communication functions:
– Which information is transmitted?
– Which data type carries the signal which transmits information?
Material flow
0-Signal 1-Signal
1-Signal 0-Signal
16. Once all the workpieces have been tested and sorted, stop the
simulation by clicking onto the Running field.
18. Hide the section of the window with the display of I/O connections
as you do not need this information. Activate the context-sensitive
menu via the right mouse button and deactivate the Show I/O
Connections command.
19. If you merely want to observe the changes in communication
signals, then set the stops at the appropriate signals. Simulation
stops as soon as the relevant signal changes its value and you can
observe the sequence at your leisure.
24. Start simulation of the system by clicking onto the Stopped button
in the status bar.
26. Fill the magazine of the distributing station with correct workpieces
again.
27. Acknowledge the activity and click onto the illuminated start button.
34. With the simulation of the system you have now analysed how
communication between the distributing and testing stations
functions.
In the GRAFCETs for the stations you can reproduce in detail how
and at which points in the PLC program communication is taken into
consideration. You will find the GRAFCETs in the technical
documentation for the stations.
35. You can analyse the communication between the testing and sorting
stations in the same way by using simulation and the technical
documentation.