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Abstract
Swiss German University has excellent FMS laboratory facility based on FESTO products. However, the
facility is limited in quantity and could not be extended easily due to the relatively high cost for extending the
facility. Consequently, the objectives of preparing students to gain real world industrial automation and the
use of laboratory facility are not optimized. In this paper a framework of an FMS for education based on
microcontrollers and fieldbus is presented. Microcontrollers are chosen due to their widespread availability,
low cost and versatility. Fieldbus is implemented by customizing existing standard bus systems such as
Modbus and Profibus, thus providing hand-on experience and control of the communication bus system. The
framework can thus strengthen the pedagogical to the students and at the same time the functionality of the
laboratory facility can be extended. Existing facility and new equipments can then be combined together as a
network, thus creating a customized FMS. Each new functional part can be developed by a group of students
according to the requirement and an agreed standard fieldbus protocol. After successfully tested
independently, each new part can then be connected to the network to forms a new node in the FMS. The
end result is a really flexible and extendable manufacturing system. The objective of extending laboratory
facility and exposing students to real world applications are thus realizable.
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Framework of Flexible Manufacturing System (FMS) for Education Based on Microcontrollers and Fieldbus
(Arko Djajadi)
20
Journal of Mechatronics, Electrical Power and Vehicular Technology ISSN 2087-0116
Vol. 0, No. 0, Juli 2010 SK No: 13/AKRED/LIPI/P2MBI/3/2011
21
Framework of Flexible Manufacturing System (FMS) for Education Based on Microcontrollers and Fieldbus
(Arko Djajadi)
their PLCs, add other relevant processing network that will be used later. Tutuko
stations, integrate all of them by means of a Prayogo and Bambang Darwis created the
serial bus / fieldbus network and complete the first FMS Simulator using Microsoft Visual
whole system with SCADA capability. Basic to support the Automation Technology
Networking with fieldbus will simplify wiring lecture and laboratory.
between stations. The main drive is to have a By networking PCs through its serial port
testbed to experiment open-endedly and to use equipped with RS232-to-RS485 converter,
low cost microcontrollers as the brain of each each PC is thus physically connected to other
node, without risking of damaging the PCs along a segment of serial cable. The FMS
existing FMS. Simulator is then run on each PC, one acting
as the master node while the rest acting as the
3.2 Microcontroller as Controlling and slave nodes.
Networking Elements
The extended FMS is based on 3.3.1.2 RS232 to RS485 Converter Card
microcontrollers which will function as the RS232 is a serial, bi-directional,
smart nodes controlling sensors and actuators asynchronously operating interface. It
attached to them. On the other hand the operates with a signal level against ground
microcontrollers with their built-in serial port and is therefore relatively interference-prone
are equipped with RS232-to-RS485 (distances of up to 30 m). RS232 is not
converters to allow multipoint-connection and designed to communicate data by more than
thus creating a simplified fieldbus network. two stations.
Figure 5 illustrates such network. Therefore, to allow multipoint
connections RS485 is used. To do so, a
converter card from RS232-to-RS485 is built.
By using a number of converter cards,
simplified fieldbus network can be realized.
The RS485 is the most widely used
hardware for fieldbus systems. It defines a
line with a maximum of 32 stations, restricted
by bus terminating resistors at both ends.
Originally it defined a data transfer rate of up
to 500 kBit/s. In the meantime, up to
12MBit/s are now realized. Depending on the
data transfer rate, distances are between
Figure 5. Master/slave system in a simplified approximately 1200 m and 200 m.
fieldbus network The RS485 operates using twisted and
screened data transfer lines. The twisted line
3.3 Components (also known as ‘twisted pair’) consists of a
The main components of the extended FMS pair of wires, which is twisted like a string.
will be explained below. Starting with some The purpose of this is to ensure that electrical
necessary inhouse developed add-ons, such as interference affects both wires simultaneously.
FMS protocol simulator, serial converter and If both wires are floating-ground or of
protocol converter, the 8 stations of extended identical potential to ground then such a
FMS are discussed. system is highly insensitive to interference, as
the signal is measured in the form of a
3.3.1 Inhouse Developed Add-Ons differential voltage signal irrespective of
Before the extended FMS can be realized, ground
there are a number of issues that must be
solved first. Each of the issue will be 3.3.1.3 Protocol Converter Card
discussed. Another problem arose when trying to
integrate the 6 DOF robot handling station to
3.3.1.1 FMS Protocol Simulator the network, as it is controlled by its
Before really starting the projects to build proprietary on-board computer. Interfacing to
the whole system of an extended FMS, the it must be accomplished through serial port,
first step is to build and test the protocol and which is normally used to upload/download
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Journal of Mechatronics, Electrical Power and Vehicular Technology ISSN 2087-0116
Vol. 0, No. 0, Juli 2010 SK No: 13/AKRED/LIPI/P2MBI/3/2011
coordinate values and instructions to/from PC. remove the workpiece from the processing
This problem is solved by designing a special station and place it on the orientating station.
protocol converter card that translates and The orientating stating will check whether the
encapsulates each packet traveling in the workpiece is upside-down or not. If so, it will
fielbus network to/from the robot handling be rectified.
station. Once the checking and orientating
operations are completed, the workpiece is
3.3.2 Stations placed on a carrier parking on the conveyor
As already stated in the purpose above, the belt. The SCADA PC then gives orders to the
idea is to create extended FMS based on MPS. conveyor station to carry the workpiece to the
There are 8 stations, and their names are designated point, from which the workpiece
distribution, testing, processing, robot will be taken away and stored in the ARS
handling[4], orientating[5], conveyor[6], station. The cycle is then repeated from the
ARS[7] and SCADA[8] stations. beginning under the control of the master
SCADA PC.
Master
Distribution Testing Processing
Robotic All communication is thus performed
SCADA Handling
Station Station Station Station along the fieldbus. The packet conversion
from RS232 format, when the packet leaves
the each node, to RS485 format is done by
RS232-to-RS485 converter attached to each
uC uC uC uC
node.
fieldbus As mentioned earlier, a special
uC uC uC
microcontroller-based protocol converter is
developed to allow the robot handling station
to be configured as a separate node, since this
station has its own proprietary built-in Zilog-
ARS Conveyor Orientating
Station Station Station based computer [9]. It accepts special robotic
commands, such “NT” for nesting or “RS” for
Figure 5. Extended FMS stations
reset, and returns specially formatted response,
which must be encapsulated correctly before
All stations are treated as nodes, assigned
transferring it in the fieldbus network. Each
unique station IDs and integrated on a
packet must be formatted to have an ID,
segment of serial bus network.
function code, data and CRC to allow correct
Microcontrollers are the brain of each node
addressing, instruction and error checking.
except the SCADA which is a PC, thus
One of the stations, the master, controls
creating a microcontroller-based fieldbus
bus access by issuing a time limited send
network.
authorization cyclically to the other stations,
i.e. the slaves. With a master/slave system,
3.4 Operations only the master has control over the bus. All
The operation of the extended FMS for the other stations, the slaves, must continually
the first three workstations (distribution, listen to the bus and can only send data via the
testing, processing) is similar to the original bus following a request by the master.
MPS described earlier. The difference is that
now these three stations are no longer
4. Lesson learned
controlled by 3 master PLCs, but by a single
Briefly will be discussed the valuable
slave microcontroller. This slave
lesson learned from developing the extended
microcontroller is functioning as one of the
FMS.
node with a unique address in a fieldbus
network, mastered by a PC designated as the
4.1 Practical Learning Process
SCADA station.
The effort has benefited tremendously to
Upon the completion of the operation in
everyone involved in the projects. It improves
the first three stations, a ready status is sent by
considerably both theoretical and practical
the slave node that controls these three
knowledge that is highly valued in
stations to the SCADA PC. The SCADA PC
mechatronics learning processes. Many
then instructs the robot handling station to
subjects learned in the classes and labs, such
23
Framework of Flexible Manufacturing System (FMS) for Education Based on Microcontrollers and Fieldbus
(Arko Djajadi)
as microcontroller and automation, are put [2]. Monika Bliesener, Sabine Scharf,
into practice in solving both challenging and “Fieldbus technology Profibus-DP”,
rewarding real life industrial problem. FESTO Workbook TP 402 Denkendorf,
Germany, 2003
4.2 What next? [3]. Jonas Berge, “SMAR The Fieldbus
As the main objective to create a Book”, Year 2002 edition
framework of FMS has already been achieved, [4]. Avioko Leksiantoro, “ Test and
the next step is to improve its reliability, Distribution Station in Flexible
functionality and flexibility that are still weak Manufacturing System”, Thesis Report
in the first version. This is an ongoing effort in Mechatronics Department SGU,
in parallel with the learning process that is 2005
expected to benefit everyone involved. [5]. Sandy Budiman, “ Prototype of a Disk
Orientating Station Controlled by the
5. Conclusion ATMEGA16 Microcontroller”, Thesis
A framework of an FMS for education Report in Mechatronics Department
based on microcontrollers and fieldbus has SGU, 2005
been developed and presented. [6]. Sugianto, “ Prototype of a Conveyor
Microcontrollers are chosen due to their System using the ATMEGA16
widespread availability, low cost and Microcontroller”, Thesis report
versatility. Fieldbus is implemented by Mechatronics Department SGU, 2005
customizing existing standard bus systems [7]. Brian Satrio Pono, “ Automatic Storage
Modbus. The end result is a really flexible and and Retrieval in Flexible
extendable learning system with modular Manufacturing System”, Thesis report
approach under the same control through a Mechatronics Department SGU, 2005
standard fieldbus network. The objective of [8]. Edward , “Flexible Manufacturing
extending laboratory facility and exposing System (FMS) integrated with
students to real world applications are thus SCADA”, Thesis report Mechatronics
realizable. Department SGU, 2005
[9]. - , “MovemasterEX - Industrial Micro-
References Robot System, Model RV-M1”,
[1]. Monika Bliesener, Ralph C. Weber, MovemasterEX Mitsubishi Manual,
“Fieldbus technology AS-Interface”, BFP-A5191E-B
FESTO Workbook TP 401 Denkendorf,
Germany, 2003
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