LEARNING ACTIVITY PACKET MECHATRONICS MULTIPLE STATION CONTROL B72001-AA10UEN

Transcription

1 MECHATRONICS LEARNING ACTIVITY PACKET MULTIPLE CONTROL B72001-AA10UEN

2 LEARNING ACTIVITY PACKET 10 MULTIPLE CONTROL INTRODUCTION To manufacture most products requires a number of steps that have to be performed. Often multiple machines or stations are positioned in series with each other. In an automated environment, each machine must be able to signal to the next machine when parts are available. This LAP review one type of communication called discrete I/O handshaking. It examines how handshaking works, some programming examples, and some examples of how handshaking is used. ITEM NEEDED Amatrol Supplied 2 or more of the following Mechatronics stations: 87-MS1 Pick and Place Feeding 87-MS2 Gauging 87-MS3 Indexing 87-MS4 Sorting and Queuing 87-MS5 Assembly 87-MS6 Torquing 87-MS7 Parts Storage 870-PS7313-AAU, 870-PS7314-AAU, or 870-PS7315-AAU Mechatronics Learning System for Siemens S one per station Siemens S70300 Programming Cable Siemens Step 7 Programming Software School Supplied Computer with Windows XP Operating System FIRST EDITION, LAP 10, REV. C Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered trademarks of Amatrol, Inc. All other brand and product names are trademarks or registered trademarks of their respective companies. Copyright 2014, 2012, 2011 by AMATROL, INC. All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any means, electronic, optical, mechanical, or magnetic, including but not limited to photographing, photocopying, recording or any information storage and retrieval system, without written permission of the copyright owner. Amatrol,Inc., 2400 Centennial Blvd., Jeffersonville, IN USA, Ph , FAX B72001-AA10UEN MULTIPLE CONTROL 2

3 TABLE OF CONTENTS SEGMENT 1 DISCRETE I/O HANDSHAKING OBJECTIVE 1 Describe the function of discrete I/O handshaking OBJECTIVE 2 Describe how to connect PLC discrete I/O handshaking lines OBJECTIVE 3 Describe the operation of a PLC program that uses discrete I/O handshaking SKILL 1 Design a PLC program to use discrete I/O handshaking SEGMENT 2 SYSTEM STARTUP/ HALT OBJECTIVE 4 Describe the operation of a PLC program that uses discrete I/O handshaking for multiple station startup SKILL 2 Design a PLC program to use discrete I/O handshaking for multiple station startup OBJECTIVE 5 Describe the operation of a PLC program that uses discrete I/O handshaking for a multiple station halt SKILL 3 Design a PLC program to use discrete I/O handshaking for a multiple station halt SEGMENT 3 SYSTEM / RESET OBJECTIVE 6 Describe the operation of a multiple station emergency stop circuit OBJECTIVE 7 Describe the operation of a PLC program that uses discrete I/O handshaking for a multiple station cycle stop SKILL 4 Design a PLC program to use discrete I/O handshaking for a multiple station cycle stop OBJECTIVE 8 Describe the operation of a PLC program that uses discrete I/O handshaking for multiple station reset SKILL 5 Design a PLC program to use discrete I/O handshaking for a multiple station reset SEGMENT 4 FMS PROGRAMMING OBJECTIVE 9 Describe the operation of a PLC program that uses discrete I/O handshaking for multiple station FMS SKILL 6 Design a PLC program to use discrete I/O handshaking for multiple station FMS OBJECTIVE 10 Describe the operation of a PLC program that uses discrete I/O handshaking for multiple station quantity production SKILL 7 Modify a PLC program to use discrete I/O handshaking for multiple station quantity production B72001-AA10UEN MULTIPLE CONTROL 3

4 SEGMENT 1 DISCRETE I/O HANDSHAKING OBJECTIVE 1 DESCRIBE THE FUNCTION OF DISCRETE I/O HANDSHAKING Multiple stations are often used to manufacture a product, with each station performing a different step of the manufacturing process. In order to safely and effectively transfer the parts from one station to another, the stations typically use some form of communication, such as Ethernet, Profibus, or discrete I/O handshaking. Discrete handshaking involves connecting discrete inputs and outputs between the stations and using the on/off signals to indicate when it is safe to perform a given operation. This type of communication typically is used for fairly short distance (less than 50 feet) communications. Figure 1 shows the connections for a basic handshaking system using a discrete I/O signal. When the Station A completes its operation on a part it turns on an output to signal Station B that it can begin its operation by transporting the part away from Station A. HANDSHAKING SIGNAL PLC IN OUT PLC IN OUT A PART CONVEYOR B Figure 1. Handshake Connection B72001-AA10UEN MULTIPLE CONTROL 4

5 In most applications, there is also a second handshake signal that allows the downstream station to communicate back to the upstream station that it is ready to receive the part. This assures that parts do not get fed into the downstream station before it is ready. This signal connects an output of the downstream station to an input of the upstream station. Once the part is fed to the next station, the transfer hardware on the upstream station (cylinder, pick and place module) moves to a safe position and then sends a signal to the downstream station that it is clear. This signal tells the downstream station that it can safely start its sequence. HANDSHAKE SIGNAL DOWNSTREAM TO UPSTREAM PLC IN OUT PLC IN OUT UPSTREAM CONVEYOR DOWNSTREAM Figure 2. 2-Way Handshake Communication Figure 3 shows how additional lines are added for a third station. PLC IN OUT PLC IN OUT PLC IN OUT A CONVEYOR B CONVEYOR C Figure 3. Handshaking with Three Stations B72001-AA10UEN MULTIPLE CONTROL 5

6 OBJECTIVE 2 DESCRIBE HOW TO CONNECT PLC DISCRETE I/O HANDSHAKING LINES Wiring handshake lines between PLC discrete I/O is done using a standard method of interfacing controllers. If each station uses a PLC with the same types of input and output modules, such as the same current and voltage level, the interfacing is straightforward. Figure 4 shows a typical wiring scheme used in PLC handshaking. The handshaking output lines from the first PLC connect to the downstream station s PLC inputs. In the example in figure 4, Station B (the downstream station) communicates to Station A (the upstream station) through two I/O terminals. The handshaking input 3 on Station A is connected to output 5 on Station B and output 7 on Station A is connected to input 1 on Station B. A IN ON - READY TO RECEIVE PART FROM A B OUT 24 VDC VDC TO PREVIOUS 8 OUT 5 ON - PART READY FOR B IN 24 VDC VDC TO NEXT 3 4 Figure 4. Wiring Scheme for I/O Handshaking B72001-AA10UEN MULTIPLE CONTROL 6

7 Station A processes parts and passes them on to Station B. However, Station A cannot pass a part on to Station B if it is busy. When Station B is ready for a part, it sets its output 5 high, which turns on Station A s input 3. This tells Station A that it can safely pass on the part. Depending on the operation of the stations, more handshaking signals may be required for the system to function properly. For example, in figure 5 Station A can set output 8 high when it detects parts made of metal. This turns on Station B s input 1, which can use this information for assembly or processing operations. Station B can then turn on output 6. This turns on Station A s input 4, which may increment a counter keeping track of the number of completed products. The figure does not show power wiring to improve clarity. A IN B READY TO RECEIVE PART INCREMENT COUNTER B OUT OUT SPARE IN METAL PART Figure 5. Example of Handshaking Diagram for Two Stations B72001-AA10UEN MULTIPLE CONTROL 7

8 OBJECTIVE 3 DESCRIBE THE OPERATION OF A PLC PROGRAM THAT USES DISCRETE I/O HANDSHAKING PLC programs that use discrete I/O handshaking include bits within the logic to turn the handshake signals on or off given the state (true or false) of the rung. The first station often turns on a handshaking output, which turns on a handshaking input in the next station and causes some action to take place. If the handshaking signal is to be passed to all connected stations, then the second station will use the handshaking input to trigger a handshaking output to the next station. This process will continue to the last station. There are certain considerations to make when inserting handshaking bits into the program. First, look at the process and determine at what point in the sequence the first station sends the handshake signal to the next station. For example, one assembly station may queue parts for another assembly station. That station will hold the parts and check its handshaking input. Once the input goes high, indicating the assembly line is ready for a part, the station releases a part to assembly station #2 and waits to get another signal. ROBOT ASSEMBLY #1 HANDSHAKING SIGNAL TO PREVIOUS IS HIGH PICK AND PLACE ASSEMBLY #2 QUEUE PART Figure 6. Determine if Next Station is Ready B72001-AA10UEN MULTIPLE CONTROL 8

9 Another important consideration is to ensure that any station transferring parts to another station is clear of the production process on the downstream station before it begins processing the part. If the downstream station begins its process as soon as its sensors see the part, it is possible that the two stations components will crash and cause damage to the equipment. This may not always be an issue, as some working components may never interfere with each other. That is why it is important to evaluate each handshaking scenario carefully. Figure 7 shows a pick and place unit (station A) that feeds a station with a traverse axis and carriage (station B). Station A places the part on station B. If station B is programmed to move the part as soon as its part present sensor sees it, the part will collide with the gripper, damaging it and possibly the z-axis cylinder of the pick and place unit. The better solution is for the carriage on station B to move after its part present sensor is on AND it receives a clear handshaking signal from station A. PICK AND PLACE TRAVERSE WITH CARRIAGE A B Figure 7. Collisions May be Possible B72001-AA10UEN MULTIPLE CONTROL 9

10 Figure 8 shows portions of programs for two PLC s communicating with each other using I/O handshaking. Station A processes a part and then places it on a fixture on Station B. After Station A has dropped off the part and moves clear of Station B, it sets handshake station clear output high. This causes Station B s handshake previous station clear input to go high indicating Station A is clear or out of the way. This makes Station B s start rung true, which enables it to begin processing the part. A PROGRAM CLEAR ìpickup Retractedî ìlinear Retractedî CLEAR TO NEXT ìvacuum Offî "Station Clear Bit" CLEAR BIT "Station Clear Bit" "Handshake -Station Clear" CLEAR H.S. SIGNAL B PROGRAM START RUNG ìstart PBî ìhalt Bitî ìslide EOT Beginningî ìh.s.-prev Station Clearî ìslide Forward Bit 1î ìslide Forward Bit 1î ìpart Raise Bit 1î T2 SP PREVIOUS CLEAR BIT Figure 8. Discrete I/O Handshaking B72001-AA10UEN MULTIPLE CONTROL 10

11 SKILL 1 DESIGN A PLC PROGRAM TO USE DISCRETE I/O HANDSHAKING Procedure Overview In this procedure, you will connect multiple stations together to run portions of the process. In the last portion of the skill, you will connect all of the stations together and run the entire process. 1. Locate the mechatronics system. 2. Figure 9 shows the nine station combinations considered to be complete systems. Keep in mind that stations can only be connected to the stations listed next to them in the chart. COMBINATIONS Pick and Place Gauging Feeding 2 Pick and Place Feeding Gauging Parts Storage 3 Pick and Place Gauging Indexing Feeding 4 Pick and Place Feeding Gauging Indexing Parts Storage 5 Pick and Place Feeding Gauging Indexing Assembly 6 Pick and Place Feeding Gauging Sorting and Queuing Assembly 7 Pick and Place Feeding Gauging Indexing Assembly Parts Storage 8 Pick and Place Feeding 9 Pick and Place Feeding 10 Pick and Place Feeding Gauging Indexing Sorting and Queuing Gauging Indexing Sorting and Queuing Gauging Indexing Sorting and Queuing Assembly Assembly Parts Storage Assembly Torquing Parts Storage Figure 9. Station Combinations B72001-AA10UEN MULTIPLE CONTROL 11

12 3. Select two stations to connect and use for the first part of this skill. 4. Review figure 10 to see if you need to make any mechanical adjustments for your station combinations. The seven stations typically are mechanically adjusted to work with a specific upstream or downstream station. If you run the stations in any order besides that listed in row 9 of figure 9, then some mechanical adjustments will have to be made in order for the parts to transfer smoothly. FIRST SECOND ADJUSTMENTS REQUIRED Gauging Parts Storage The power slide will have to be loosened and moved toward the Gauging station so that the grippers can pick up the part. Then, once that is set, the location tabs on top of the slide will have to be readjusted so that the gripper stops in line with the storage bays. Gauging Sort and Queuing The traverse will have to be loosened and moved away from the Sorting and Queuing station about 1/2 inch to prevent the conveyor from rubbing on the traverse frame. The traverse axis will then have to be fastened down tightly again. Indexing Assembly The robot pickup location will have to be re-taught. Indexing Parts Storage Some adjustment to the power slide may be necessary so the gripper can pick up off the indexing table. The transfer cylinder extend on the indexing station will need to be disabled so the Part Storage gripper can pick the part up. Figure 10. Station Adjustments NOTE Be sure to use a plastic parts bin where needed to catch parts. NOTE If you are using Station Combination #6, the valve bodies must be inserted into the parts feeder in the correct orientation for the assembly station. This is because there is no Indexing station to reorient the part. 5. Locate your program files for the stations you selected. You will modify the last programs you wrote for these stations. These are the programs that include the Auto/Manual/Reset functions. 6. Modify each PLC program given the following information. The individual programs should still operate as before, but with the additional functions. The general sequence and the Handshaking/E-Stop portion of the I/O diagram (same for each station) are as follows: B72001-AA10UEN MULTIPLE CONTROL 12

13 General Sequence: 1. The Start pushbutton on each station will have to be pressed to start the individual stations. 2. When the first of the stations has completed its sequence and is ready to transport the part to the downstream station, it checks to see if the downstream station is ready (I0.7 for the first station, Q4.2 for the downstream station). When the downstream station ready signal is high, the part is transferred to the downstream station. Once the downstream station has the part, the first station returns to its home position. After it is clear of the downstream station it signals that station (Q4.3 from the first station, I0.4 for the next station) that it is clear so that it can begin processing the part. 3. The process will continue until the stations run out of parts. Special Conditions: The sequence cannot be started unless each station has their Output Power enabled, is Reset, and placed in Auto mode. The E-Stop pushbutton on any station will stop all stations and cause the E-Stop lights to blink (already hardwired). Each station must have its Output Power restored, in-process parts removed, be Reset and placed back into Auto mode before operations can start again from the beginning of the sequence. I/O DIAGRAM OUTPUT POWER ENABLED I0.3 HANDSHAKE 1 PREVIOUS I0.4 Q4.1 Q4.2 HANDSHAKE 1 TO PREVIOUS HANDSHAKE 2 TO PREVIOUS HANDSHAKE 2 PREVIOUS I0.5 HANDSHAKE 1 NEXT I0.6 Q4.3 Q4.4 HANDSHAKE 1 TO NEXT HANDSHAKE 2 TO NEXT HANDSHAKE 2 NEXT I0.7 Figure 11. I/O Diagram for Handshaking B72001-AA10UEN MULTIPLE CONTROL 13

14 Figure 12 shows the station-to-station PLC communication connections via a 9-pin cable. The input and output terminals from the PLC s that are used in the handshaking are wired to an external port, which allows easy cabling between the PLC s to enable the discrete I/O communications. The PLC inputs and outputs that are wired to each female DB-9 connector include four handshaking lines, two input and two output, which are user assignable, one system common, one +24VDC, one upstream or downstream station +24VDC, and one each user configurable input and output. There are also two emergency stop input and output signals for either next station or previous station. A PLC IN OUT I0.4 Q4.1 H.S. INPUT 1 FROM PREVIOUS B PLC IN OUT I0.4 Q4.1 H.S. OUTPUT 1 TO PREVIOUS H.S. INPUT 1 FROM NEXT H.S. INPUT 2 FROM NEXT I0.5 I0.6 I0.7 Q4.2 Q4.3 Q4.4 H.S. OUTPUT 1 TO NEXT H.S. INPUT 2 FROM PREVIOUS I0.5 I0.6 I0.7 Q4.2 Q4.3 Q4.4 H.S. OUTPUT 2 TO PREVIOUS H.S. OUTPUT 2 TO NEXT PIN TO 9-PIN CABLE PIN Station A Pin Out Description Handshake Output 1 Handshake Output 2 Handshake Input 1 Handshake Input 2 System Common Next Station +24VDC Next Station E-Stop Signal In Next Station E-Stop Signal Out 24VDC PIN Station B Pin Out Description Handshake Intput 1 Handshake Intput 2 Handshake Output 1 Handshake Output 2 System Common 24VDC Previous Station E-Stop Signal In Previous Station E-Stop Signal Out Previous Station +24VDC Figure 12. PLC Communication Connections B72001-AA10UEN MULTIPLE CONTROL 14

15 7. Perform the following substeps to open the PLC programming software. A. Make sure that the interface from the personal computer to the PLC is connected. B. Power up the PC and monitor. C. Start the SIMATIC Manager. 8. Perform the following substeps to create a project. A. Open the project that you are going to edit. B. Save the Project as L10S1STAXXXX. This is Lap 10, Skill 1. Replace the X s with the station you are working on, followed by your initials. C. Enter your edits that you developed in Step 6. D. Save your project. 9. Repeat Step 8 for the other station you selected. 10. Perform the following substeps to connect the stations together. Note that this is the opposite procedure used to disconnect the stations. A. Position the stations side by side, lining up the front and back of the work surfaces. B. Install the thumbscrews into the connecting fasteners (2) to securely hold the stations together. C. Connect the 9-pin to 9-pin cable to the 9-pin ports on each station. These are the ports that are closest to each other. Figure Pin Cable Location 9-PIN CABLE LOCATION B72001-AA10UEN MULTIPLE CONTROL 15

16 D. Install the pneumatic hose from the first station to the second station. Remember that the hose runs through the holes in the side panels. FIRST ADJOINING 'S PNEUMATIC HOSE Figure 14. Install the Pneumatic Hose E. Install the power cord from the first station to the second station. Again, this runs through the holes in the side panels. FIRST ADJOINING 'S POWER CORD POWER CORD Figure 15. Power Cord Installed F. If either station needs a feed stand or a parts bin installed, install them now. B72001-AA10UEN MULTIPLE CONTROL 16

17 11. Perform the following safety check before you begin working on the station. Make sure that you can answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Remove all obstructions from the work area Check for signs of damage to the equipment Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc. Tie up long hair Remove any robot teach pendants from the work area Locate the emergency stop button Ensure that safety glasses are worn by people in the area Ensure that all people are outside any work envelopes Figure 16. Mechatronics Safety Check 12. Connect an air supply line to the first station s air manifold quick connect. 13. Plug the first station s power cable into a power outlet. 14. Perform the following substeps to power up both stations. A. Place the Mode selector switches in the Manual position. B. Remove the lockout/tagout devices from the electrical power sources. C. Remove the lockout/tagout devices from the pneumatic power sources. D. Turn on air to the stations by shifting the levers on the lockout valves. E. Set the stations air supply regulators according to the following chart. AIR SUPPLY SETTINGS Station Main Regulator Auxiliary Regulator 87-MS1 50 psi/345 kpa 40 psi/276 kpa 87-MS2 50 psi/345 kpa 87-MS3 50 psi/345 kpa 87-MS4 50 psi/345 kpa 87-MS5 50 psi/345 kpa 12 psi/83 kpa 87-MS6 50 psi/345 kpa 87-MS7 50 psi/345 kpa Figure 17. Station Air Supply Settings B72001-AA10UEN MULTIPLE CONTROL 17

18 F. Turn the stations Main Power switch to the On position. 15. Perform the following substeps to download the project to the PLC of one of the stations. A. Place the PLC power supply switch in the On position. B. Place the Mode Selector switch in the Run position. C. Reset the PLC. D. Download the SIMATIC 300 Station object for that station to the PLC. Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart. E. Click Yes on the dialog to complete a warm restart. 16. Repeat Step 14 for the other station. Note that you do have to connect the cable to the other PLC to download the project to that PLC. 17. Go online with one of the processors and monitor that project. 18. Press the Output Power pushbutton on each station to enable the PLCs outputs. 19. Perform the following substeps to test the operation of the program. NOTE If the first station you are using does not have a feeder, you will have to continue to place parts in the start position for it to continue operating. You should not, however, have to press the Start pushbutton each time. A. Turn each Mode Selector switch to Reset to make sure the stations are homed. B. Stock all feeders or place a part in the start position on the first station. Pay attention to valve body orientation. C. Turn each Mode Selector switch to Auto mode. The Start pushbutton lights should be off at this time. If either light is blinking, something is not reset or a feeder is empty. D. Press and release the Start pushbutton on each station. You should see the first station move through its sequence. When it has completed its sequence, it should then pass the part on to the downstream station, or the downstream station will pick up the part. The second station should then complete its sequence and wait for the next part. B72001-AA10UEN MULTIPLE CONTROL 18

19 If you are using the Gauging, Orientation, Sorting and Queuing, or Parts Storage stations, test aluminum and acrylic valve bodies to verify that the stations are fully functional. E. Run several parts through the stations to verify that they operate correctly. If the handshaking does not seem to function as it should, examine the handshaking I/O lights to make sure they are coming on when they should during your program. 20. Go to Step 2 and select another pair of stations to work with using figure 9 as your guide. Use figure 10 in Step 4 to see if any mechanical adjustments are required. Remember to remove any feed stands or parts bins before connecting another station to that side. Add feed stands or parts bins where necessary. 21. Repeat Steps 4-19 for the new station(s). 22. Repeat Steps 20 and 21 until you have all of your stations connected and running together. 23. Click the Monitor button to go offline from the processor you are currently working on. 24. Print out a copy of all of your ladder logic programs and place them in your portfolio. They will be used in your assessment. 25. Perform the following substeps to shut down the stations. A. Close the LAD/STL/FBD Editor on the PC. B. Close the SIMATIC Manager on the PC. C. Turn off the PC and monitor. D. Turn each station s Main Power switch to Off. E. Perform a lockout/tagout on each station s electrical power source. F. Perform a lockout/tagout on each station s pneumatic power source. B72001-AA10UEN MULTIPLE CONTROL 19

20 SEGMENT 1 SELF REVIEW 1. Three communication methods used between multiple stations are Ethernet, discrete I/O handshaking, and. 2. Most applications include handshaking upstream and to ensure stations are ready to pass or receive parts. 3. Handshake wiring between PLC s is straightforward only if each station uses PLC s with the same types of. 4. Some examples of handshake usage are: station ready, increment a counter and pass on a part s of construction. 5. Discrete I/O handshaking uses the PLC logic bits to turn the handshake signals. 6. Before including handshaking signals within a PLC program, first look at the to determine where the handshake signals should be examined. B72001-AA10UEN MULTIPLE CONTROL 20

21 START START HALT CYCLE OUTPUT POWER RESET PRODUCTION COUNT EMERGENCY POWER ON OFF START RESET OUTPUT POWER EMERGENCY POWER ON OFF START RESET OUTPUT POWER EMERGENCY POWER ON OFF SEGMENT 2 SYSTEM STARTUP/ HALT OBJECTIVE 4 DESCRIBE THE OPERATION OF A PLC PROGRAM THAT USES DISCRETE I/O HANDSHAKING FOR MULTIPLE STARTUP Because most manufacturing lines are large and consist of many different pieces of equipment, they often have a master start pushbutton that will start the whole process. This way, the operator does not have to go around the line and push the start button on each machine separately. A master start pushbutton can be located on a separate master control panel that contains other multiple station controls as well or it may be located on the first station s operator panel, as shown in figure 18. This station is either wired directly to each individual station, or wired to the first station and then handshaking lines are used to pass the signal from the station throughout the rest of the system. 1 CONTROLS START SIGNAL 2 START SIGNAL 3 CONTROLS START PUSHBUTTON Figure 18. Master Start Pushbutton B72001-AA10UEN MULTIPLE CONTROL 21

22 A master start pushbutton requires a separate handshaking line in addition to those used to pass parts from one station to the next. Figure 19 shows a wiring diagram that incorporates a master start handshaking line between each station. In this example, when the operator presses the master start pushbutton on Station 1, the PLC at Station 1 turns on output 8 to signal Station 2 to start, and Station 2 s PLC in turn turns on its output 8 to signal Station 3 to start IN OUT IN START INPUT START PASSED TO 3 OUT IN OUT START PUSHBUTTON TURNS ON OUTPUT START Figure 19. Wiring Diagram for Master Start The logic used in each PLC to create a master start function adds a handshaking bit in parallel to the start pushbutton in the start rung logic normally used to start the station. It does not replace the start pushbutton in the startup rung, as there may be instances where the start pushbutton is needed to run the individual piece of equipment. B72001-AA10UEN MULTIPLE CONTROL 22

23 The example shown in figure 20 shows that pushing the master start pushbutton on Station 1 turns on the master start output. This output turns on the master start handshaking input on the station. This input bit is in parallel to the station s start pushbutton, so either signal, along with the other conditions in the rung, will make the output true. This enables the station to start its process. Notice the last rung in the example. This rung also has the master start input, but this rung simply sets another handshaking output to pass the master start signal to the next station. The next station s program would be similar to the station rungs in figure 20, with the master start input in parallel to the station start input. That station would also pass the master start signal on to the next station, if applicable. START ìmaster Start PB" CONTROL PANEL ON 1 "Master Start" HANDSHAKE FROM START TO "Master Start" OUTPUT TO START RUNG 1 ìstart PB" ìslide BOTî ìmemory Bit 1î ìmemory Bit 2î ìstation Readyî "Master Start" START SIGNAL IN PARALLEL WITH START P.B. START TO NEXT INPUT TO FROM CONTROL PANEL "Master Start" "Master Start Handshake To Next Station" HANDSHAKE FROM CONTROL PANEL PASSED FROM 1 TO 2 Figure 20. Master Start Programming Example B72001-AA10UEN MULTIPLE CONTROL 23

24 SKILL 2 DESIGN A PLC PROGRAM TO USE DISCRETE I/O HANDSHAKING FOR MULTIPLE STARTUP Procedure Overview In this procedure, you will modify your programs from the previous skill to provide a master startup function. Because this system does not have a master control panel, you will use the controls on station 1. This will enable you to start the entire system with the Start pushbutton on the first station. 1. Locate the mechatronics system. 2. Verify all of the stations are fastened together and air and power lines are connected. If they are not, connect them. 3. Locate your programs for the stations that you modified in the last skill. You will modify these programs to enable a master start function. 4. Modify each PLC program so that the Start pushbutton on the first station will start all of the stations. The individual programs should still operate as before, but with the additional functions. B72001-AA10UEN MULTIPLE CONTROL 24

25 I/O DIAGRAM OUTPUT POWER ENABLED I0.3 HANDSHAKE 1 PREVIOUS I0.4 Q4.1 Q4.2 HANDSHAKE 1 TO PREVIOUS HANDSHAKE 2 TO PREVIOUS HANDSHAKE 2 PREVIOUS I0.5 HANDSHAKE 1 NEXT I0.6 Q4.3 Q4.4 HANDSHAKE 1 TO NEXT REMOTE START TO NEXT HANDSHAKE 2 NEXT I0.7 REMOTE START FROM PREVIOUS REMOTE START TO NEXT Figure 21. I/O Diagram for Master Start 5. Perform the following substeps to open the PLC programming software. A. Make sure that the interface from the personal computer to the PLC is connected. B. Power up the PC and monitor. C. Start the SIMATIC Manager. 6. Perform the following substeps to create a project. A. Open the project that you are going to edit. B. Save the Project as L10S2STAXXXX. This is Lap 10, Skill 2. Replace the X s with the station you are working on, followed by your initials. C. Enter your edits that you developed in Step 4. D. Save your project. 7. Repeat Step 6 for the other stations. B72001-AA10UEN MULTIPLE CONTROL 25

26 8. Perform the following safety check before you begin working on the system. Make sure that you can answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Remove all obstructions from the work area Check for signs of damage to the equipment Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc. Tie up long hair Remove any robot teach pendants from the work area Locate the emergency stop button Ensure that safety glasses are worn by people in the area Ensure that all people are outside any work envelopes Figure 22. Mechatronics Safety Check 9. Connect an air supply line to the first station s air manifold quick connect. 10. Plug the first station s power cable into a power outlet. 11. Perform the following substeps to power up the stations. A. Place the Mode selector switches in the Manual position. B. Remove the lockout/tagout devices from the electrical power sources. C. Remove the lockout/tagout devices from the pneumatic power sources. D. Turn on air to the stations by shifting the levers on the lockout valves. E. Set the stations air supply regulators according to the following chart. AIR SUPPLY SETTINGS Station Main Regulator Auxiliary Regulator 87-MS1 50 psi/345 kpa 40 psi/276 kpa 87-MS2 50 psi/345 kpa 87-MS3 50 psi/345 kpa 87-MS4 50 psi/345 kpa 87-MS5 50 psi/345 kpa 12 psi/83 kpa 87-MS6 50 psi/345 kpa 87-MS7 50 psi/345 kpa Figure 23. Station Air Supply Settings F. Turn the stations Main Power switch to the On position. B72001-AA10UEN MULTIPLE CONTROL 26

27 12. Perform the following substeps to download the project to the PLC. A. Place the PLC power supply switch in the On position. B. Place the Mode Selector switch in the Run position. C. Reset the PLC. D. Download the SIMATIC 300 Station object for that station to the PLC. Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart. E. Click Yes on the dialog to complete a warm restart. 13. Repeat Step 12 for the other stations. Note that you do have to connect the cable to the other PLCs to download the projects to them. 14. Go online with one of the processors and monitor that project. 15. Press the Output Power pushbutton on each station to enable the PLCs outputs. 16. Perform the following substeps to test the operation of the program. A. Turn each Mode Selector switch to Reset to make sure the stations are homed. B. Stock all feeders or place a part in the start position on the first station. C. Turn each Mode Selector switch to Auto mode. The Start pushbutton lights should be off at this time. If any lights are blinking, something is not reset or a feeder is empty. D. Press and release the Start pushbutton on the first station. You should see the first station run its sequence and then pass the part on to the downstream station, which should start automatically. This should continue through all of the stations. E. Run three parts through the stations to verify the programs operate correctly. 17. Click the Monitor button to go offline from the processor you are currently working on. 18. Print out a copy of all of your ladder logic programs and place them in your portfolio. They will be used in your assessment. 19. Perform the following substeps to shut down the stations. A. Close the LAD/STL/FBD Editor on the PC. B. Close the SIMATIC Manager on the PC. C. Turn off the PC and monitor. D. Turn each station s Main Power switch to Off. E. Perform a lockout/tagout on each station s electrical power source. F. Perform a lockout/tagout on each station s pneumatic power source. B72001-AA10UEN MULTIPLE CONTROL 27

28 START START HALT CYCLE OUTPUT POWER RESET PRODUCTION COUNT EMERGENCY POWER ON OFF START RESET OUTPUT POWER EMERGENCY POWER ON OFF START RESET OUTPUT POWER EMERGENCY POWER ON OFF OBJECTIVE 5 DESCRIBE THE OPERATION OF A PLC PROGRAM THAT USES DISCRETE I/O HANDSHAKING FOR A MULTIPLE HALT Master controls often include a multiple station or master halt button. This enables the operator to halt all of the stations at the end of the current sequence step and then restart the stations with the start pushbutton. This is useful when the operator needs to temporarily stop the operation. The halt does not take the place of an emergency stop HALT PUSHBUTTON CONTROLS HALT SIGNAL HALT SIGNAL CONTROLS Figure 24. Master Halt Pushbutton The multiple station halt is operated through handshaking lines. If discrete I/O is used, additional lines beyond those used for passing parts to the next station are typically used. A master stop signal would use a handshaking output from the master control panel, triggered by its stop pushbutton. Because this signal would work the same as the stop pushbutton signal on each subsequent station, the handshaking bit would be in series with the stop pushbutton signal. It does not replace the stop pushbutton in the halt rung, as there may be instances where the stop pushbutton is needed to stop the individual piece of equipment. The master halt signal will be passed from station to station until all of the stations are halted. Figure 25 shows that when the master control halt pushbutton is pushed, it turns on a master halt output to the station. This triggers the station s master halt handshake input, which activates the station s halt programming. The input handshake signal also triggers a master halt output handshake signal to the next station. This process continues until all of the stations are halted. Pressing the start pushbutton on the individual stations has no affect because the master halt signal is branched around the start pushbutton signal in the halt rung. The stations will resume operation only when the master start pushbutton is pressed. B72001-AA10UEN MULTIPLE CONTROL 28

29 HALT CONTROL PANEL ON 1 ìhalt PB" ìstart PB" "Master Halt Handshake to Station" "Master Halt" HALT SIGNAL TURNS ON HALT OUTPUT TO S HALT RUNG ìstop PB" ìstart PBî 1 START IS INACTIVE WHEN HALT IS USED ìhalt Bitî HANDSHAKE FROM CONTROL PANEL ìhalt Bitî "Master Halt" HALT HALT SIGNAL IS PARALLEL TO HALT HALT TO NEXT "Master Haltî "Master Halt Handshake To Next Station" PASSES HALT TO NEXT Figure 25. Master Halt Programming Example B72001-AA10UEN MULTIPLE CONTROL 29

30 SKILL 3 DESIGN A PLC PROGRAM TO USE DISCRETE I/O HANDSHAKING FOR A MULTIPLE HALT Procedure Overview In this procedure, you will modify your programs from the previous skill to provide a multiple station halt function. This will enable you to halt the entire system from the first station. 1. Locate the mechatronics system. 2. Verify that two of the stations are fastened together and air and power lines are connected. If they are not, connect them. 3. Locate your programs for the stations that you modified in the last skill. You will modify these programs to enable a master halt function. 4. Modify each PLC program so that the Stop pushbutton on the first station will stop both stations at the end of their current sequence step. The Start pushbutton on the first station will drop the master halt and resume operations on that station. The Start pushbutton on the second station will not allow the station to resume until the Start pushbutton on the first station is pressed, turning off the master halt in the second station s logic. The master halt will use the same I/O used for the master start in the last skill (input I0.5 and output Q4.4). Additional handshake lines were not included because automated systems typically use a network such as Profibus to send all of the handshake signals over one line. The individual programs should still operate as before, but with the master halt function rather than with the master start. B72001-AA10UEN MULTIPLE CONTROL 30

31 I/O DIAGRAM OUTPUT POWER ENABLED I0.3 HANDSHAKE 1 PREVIOUS I0.4 HANDSHAKE 2 PREVIOUS I0.5 HANDSHAKE 1 NEXT I0.6 Q4.1 Q4.2 Q4.3 Q4.4 HANDSHAKE 1 TO PREVIOUS HANDSHAKE 2 TO PREVIOUS HANDSHAKE 1 TO NEXT HANDSHAKE 2 TO NEXT HANDSHAKE 2 NEXT I0.7 HALT TO NEXT HALT FROM PREVIOUS Figure 26. I/O Diagram for Multiple Station Halt 5. Perform the following substeps to open the PLC programming software. A. Make sure that the interface from the personal computer to the PLC is connected. B. Power up the PC and monitor. C. Start the SIMATIC Manager. 6. Perform the following substeps to create a project. A. Open the project that you are going to edit. B. Save the Project as L10S3STAXXXX. This is Lap 10, Skill 3. Replace the X s with the station you are working on, followed by your initials. C. Enter your edits that you developed in Step 4. D. Save your project. B72001-AA10UEN MULTIPLE CONTROL 31

32 7. Repeat Step 6 for the other station. 8. Perform the following safety check before you begin working on the system. Make sure that you can answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Remove all obstructions from the work area Check for signs of damage to the equipment Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc. Tie up long hair Remove any robot teach pendants from the work area Locate the emergency stop button Ensure that safety glasses are worn by people in the area Ensure that all people are outside any work envelopes Figure 27. Mechatronics Safety Check 9. Connect an air supply line to the first station s air manifold quick connect. 10. Plug the first station s power cable into a power outlet. 11. Perform the following substeps to power up the stations. A. Place the Mode selector switches in the Manual position. B. Remove the lockout/tagout devices from the electrical power sources. C. Remove the lockout/tagout devices from the pneumatic power sources. D. Turn on air to the stations by shifting the levers on the lockout valves. E. Set the stations air supply regulators according to the following chart. AIR SUPPLY SETTINGS Station Main Regulator Auxiliary Regulator 87-MS1 50 psi/345 kpa 40 psi/276 kpa 87-MS2 50 psi/345 kpa 87-MS3 50 psi/345 kpa 87-MS4 50 psi/345 kpa 87-MS5 50 psi/345 kpa 12 psi/83 kpa 87-MS6 50 psi/345 kpa 87-MS7 50 psi/345 kpa Figure 28. Station Air Supply Settings F. Turn the stations Main Power switch to the On position. B72001-AA10UEN MULTIPLE CONTROL 32

33 12. Perform the following substeps to download the project to the PLC. A. Place the PLC power supply switch in the On position. B. Place the Mode Selector switch in the Run position. C. Reset the PLC. D. Download the SIMATIC 300 Station object for that station to the PLC. Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart. E. Click Yes on the dialog to complete a warm restart. 13. Repeat Step 12 for the other station. Note that you do have to connect the cable to the other PLCs to download the projects to them. 14. Go online with one of the processors and monitor that project. 15. Press the Output Power pushbutton on each station to enable the PLCs outputs. 16. Perform the following substeps to test the operation of the program. A. Turn each Mode Selector switch to Reset to make sure the stations are homed. B. Stock all feeders. C. Turn each Mode Selector switch to Auto mode. The Start pushbutton lights should be off at this time. If any of the lights are blinking, something is not reset or a feeder is empty. D. Press and release the Start pushbutton on each station. The system should run through the complete operation. E. Run three complete sequences through each station to verify the system operates correctly. F. Once the first station starts running the next sequence press the Stop pushbutton on the first station. You should observe both stations stop at the end of their current sequence steps and the Start pushbutton active lamps turn off. The Output Power on each station should still be on. G. Press and release the Start pushbutton on each station, beginning with the first station. You should observe both stations start where they left off. H. Repeat substeps F and G several times during the sequences, verifying the stations all stop and recover, as they should. B72001-AA10UEN MULTIPLE CONTROL 33

34 17. Click the Monitor button to go offline from the processor you are currently working on. 18. Print out a copy of both of your ladder logic programs and place them in your portfolio. They will be used in your assessment. 19. Perform the following substeps to shut down the stations. A. Close the LAD/STL/FBD Editor on the PC. B. Close the SIMATIC Manager on the PC. C. Turn off the PC and monitor. D. Turn each station s Main Power switch to Off. E. Perform a lockout/tagout on each station s electrical power source. F. Perform a lockout/tagout on each station s pneumatic power source. B72001-AA10UEN MULTIPLE CONTROL 34

35 SEGMENT 2 SELF REVIEW 1. Large manufacturing lines often include a master start signal on a to start all of the equipment. 2. The master start signal is in to the station s start pushbutton signal in the station logic. 3. To pass the master start signal from one station to the next, each station uses the to turn on the master start output to the next station. 4. A master halt pushbutton enables the operator to all of the stations. 5. The stations (do/do not) have to be reset after the master halt pushbutton is used. 6. The master halt handshaking bit is in to the station s stop pushbutton signal. B72001-AA10UEN MULTIPLE CONTROL 35

36 SEGMENT 3 SYSTEM /RESET OBJECTIVE 6 DESCRIBE THE OPERATION OF A MULTIPLE EMERGENCY CIRCUIT Multiple station manufacturing lines usually have several emergency stop pushbuttons installed in various places. This is in part because of the National Fire Protection Association s standard 79, which regulates electrical standards for industrial machinery. This code states that emergency stop pushbuttons must be located at each operator control station and at other locations where an emergency stop is required. These emergency stops are part of a multiple station emergency stop, where any of the stop buttons will stop all stations. E-S WIRING CONNECTS ALL S E-S Figure 29. Multiple Station Emergency Stop B72001-AA10UEN MULTIPLE CONTROL 36

37 Multiple station emergency stop circuits are typically hard wired to safety relays, although the trend (and industry standards) is starting toward the use of some safety PLCs on networks such as Profibus and DeviceNet. A safety PLC uses separate channels for the safety portion of the controls. Generally there are at least two channels (microprocessors) that perform exactly the same logic, check against each other and write the outputs only if there is agreement between them. This provides redundancy in the system. If one of the channels fails, then the other one provides a backup. The microprocessors check each other often to make sure they are operating correctly. A basic operational diagram is shown in figure 31. Figure 30. Safety PLC siemens AG2006, ALL RIGHTS RESERVED MICROPROCESSOR MICROPROCESSOR IN IN OUT OUT MICROPROCESSORS CHECK LOGIC AGAINST EACH OTHER OUTPUTS TO DEVICES WRITES OUTPUTS ONLY IF THE MICROPROCESSORS AGREE WITH EACH OTHER Figure 31. Safety PLC Operational Diagram B72001-AA10UEN MULTIPLE CONTROL 37

38 START START HALT CYCLE OUTPUT POWER RESET PRODUCTION COUNT EMERGENCY POWER ON OFF START RESET OUTPUT POWER EMERGENCY POWER ON OFF START RESET OUTPUT POWER EMERGENCY POWER ON OFF OBJECTIVE 7 DESCRIBE THE OPERATION OF A PLC PROGRAM THAT USES DISCRETE I/O HANDSHAKING FOR A MULTIPLE CYCLE Most large manufacturing lines incorporate a multiple station or master cycle stop pushbutton. A multiple station cycle stop allows for an orderly shutdown of the manufacturing line. Each station typically is allowed to finish the parts in process and then the station is stopped. Operators generally use a master cycle stop at the end of a shift. 1 CONTROLS CYCLE SIGNAL 2 CYCLE SIGNAL 3 CONTROLS CYCLE Figure 32. Master Cycle Stop Pushbutton B72001-AA10UEN MULTIPLE CONTROL 38

39 The multiple station cycle stop is operated through a handshaking line. A master stop signal would use a handshaking output from the master control panel, triggered by its stop pushbutton. Because either this signal or the stop pushbutton signal on each subsequent station will stop that station, the handshaking bit would be in series with the stop pushbutton signal. It does not replace the stop pushbutton in the stop rung, as there may be instances where the stop pushbutton is needed to stop the individual piece of equipment. Figure 33 shows how the master cycle stop pushbutton turns on a master cycle stop output handshake signal to the station. This turns on the station s master cycle stop handshake input, which then disables the start bit rung, stopping the station. This prevents the station from resuming the next cycle. The start pushbutton on the station will restart the station operations. The handshake input also turns on the station s master cycle stop handshake output to pass the master cycle stop on to the next station. This process will continue until all of the stations are stopped. CYCLE ìmaster Cycle Stop PB" CONTROL PANEL ON 1 "Master Cycle Stop Handshake to Station" START BIT LOGIC 1 CYCLE SIGNAL TURNS ON CYCLE TO S ìstop PB" ìmaster Cycle Stop Handshake From Master Control Panel ìstart PB" ìstart Bitî CYCLE TO NEXT ìstart Bitî CYCLE PREVENTS START RUNG FROM BEING TRUE ìmaster Cycle Stop Handshake From Master Control Panel "Master Cycle Stop Handshake To Next Station" CYCLE IS PASSED TO NEXT Figure 33. Master Cycle Stop Programming Example B72001-AA10UEN MULTIPLE CONTROL 39

40 SKILL 4 DESIGN A PLC PROGRAM TO USE DISCRETE I/O HANDSHAKING FOR A MULTIPLE CYCLE Procedure Overview In this procedure, you will modify your programs from the previous skill to provide a multiple station cycle stop function. This will enable you to perform a cycle stop on the entire system from the first station. 1. Locate the mechatronics system. 2. Verify two of the stations are fastened together and air and power lines are connected. If they are not, connect them. 3. Locate your programs for the stations that you modified in the last skill. You will modify these programs to enable a master cycle stop function. 4. Modify each PLC program so that the Stop pushbutton on the first station will stop both of the stations at the end of their sequence. The Start pushbuttons on each station will begin a new sequence. The master cycle stop will use the same I/O used for the master halt in the last skill. The individual programs should still operate as before, but with the master cycle stop function rather than with the master halt. B72001-AA10UEN MULTIPLE CONTROL 40

41 I/O DIAGRAM OUTPUT POWER ENABLED I0.3 HANDSHAKE 1 PREVIOUS I0.4 HANDSHAKE 2 PREVIOUS I0.5 HANDSHAKE 1 NEXT I0.6 Q4.1 Q4.2 Q4.3 Q4.4 HANDSHAKE 1 TO PREVIOUS HANDSHAKE 2 TO PREVIOUS HANDSHAKE 1 TO NEXT HANDSHAKE 2 TO NEXT HANDSHAKE 2 NEXT I0.7 CYCLE FROM PREVIOUS CYCLE TO NEXT Figure 34. I/O Diagram for Multiple Station Cycle Stop 5. Perform the following substeps to open the PLC programming software. A. Make sure that the interface from the personal computer to the PLC is connected. B. Power up the PC and monitor. C. Start the SIMATIC Manager. 6. Perform the following substeps to create a project. A. Open the project that you are going to edit. B. Save the Project as L10S4STAXXXX. This is Lap 10, Skill 4. Replace the X s with the station you are working on, followed by your initials. C. Enter your edits that you developed in Step 4. D. Save your project. 7. Repeat Step 6 for the other station. B72001-AA10UEN MULTIPLE CONTROL 41

42 8. Perform the following safety check before you begin working on the system. Make sure that you can answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Remove all obstructions from the work area Check for signs of damage to the equipment Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc. Tie up long hair Remove any robot teach pendants from the work area Locate the emergency stop button Ensure that safety glasses are worn by people in the area Ensure that all people are outside any work envelopes Figure 35. Mechatronics Safety Check 9. Connect an air supply line to the first station s air manifold quick connect. 10. Plug the first station s power cable into a power outlet. 11. Perform the following substeps to power up the stations. A. Place the Mode selector switches in the Manual position. B. Remove the lockout/tagout devices from the electrical power sources. C. Remove the lockout/tagout devices from the pneumatic power sources. D. Turn on air to the stations by shifting the levers on the lockout valves. E. Set the stations air supply regulators according to the following chart. AIR SUPPLY SETTINGS Station Main Regulator Auxiliary Regulator 87-MS1 50 psi/345 kpa 40 psi/276 kpa 87-MS2 50 psi/345 kpa 87-MS3 50 psi/345 kpa 87-MS4 50 psi/345 kpa 87-MS5 50 psi/345 kpa 12 psi/83 kpa 87-MS6 50 psi/345 kpa 87-MS7 50 psi/345 kpa Figure 36. Station Air Supply Settings F. Turn the stations Main Power switch to the On position. B72001-AA10UEN MULTIPLE CONTROL 42

43 12. Perform the following substeps to download the project to the PLC. A. Place the PLC power supply switch in the On position. B. Place the Mode Selector switch in the Run position. C. Reset the PLC. D. Download the SIMATIC 300 Station object for that station to the PLC. Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart. E. Click Yes on the dialog to complete a warm restart. 13. Repeat Step 12 for the other station. Note that you do have to connect the cable to the other PLCs to download the projects to them. 14. Go online with one of the processors and monitor that project. 15. Press the Output Power pushbutton on each station to enable the PLCs outputs. 16. Perform the following substeps to test the operation of the program. A. Turn each Mode Selector switch to Reset to make sure the stations are homed. B. Stock all feeders. C. Turn each Mode Selector switch to Auto mode. The Start pushbutton lights should be off at this time. If any of the lights are blinking, something is not reset or a feeder is empty. D. Press and release the Start pushbutton on each station. The system should run through the complete operation. E. Run three complete sequences through each station to verify the system operates correctly. F. Once the first station starts running the next sequence press the Stop pushbutton on the first station. You should observe both stations complete their current sequence of operations then stop. The Start pushbutton active lamps also turn off. The Output Power on each station should still be on. G. Press and release the Start pushbutton on each station. You should observe all stations start a new sequence when a part is ready. H. Repeat substeps F and G several times during the sequences, verifying the stations all stop and recover, as they should. B72001-AA10UEN MULTIPLE CONTROL 43

44 17. Perform the following substeps to test your Emergency Stop handshaking. NOTE The mechatronics system does not use safety PLC s described in a previous objective for emergency stops. The emergency stop circuits are all hardwired to station relays that drop all electrical power to the station. A. Turn each Mode Selector switch to Reset to make sure the stations are homed. B. Stock all feeders or place a part in the start position on the first station. C. Turn each Mode Selector switch to Auto mode. D. Press and release the Start pushbutton. E. Once the first station starts running press the Emergency Stop pushbutton. You should observe both stations stop and the E-Stop pushbutton lights on both stations blinking. The Output Power on each station should have dropped out. F. Pull out the Emergency Stop pushbutton. The E-Stop pushbutton lights should be off, but the station should still be stopped. 18. Perform the following substeps to recover from the Emergency Stop. A. Remove any parts on the station work surfaces or in grippers. B. Press the Output Power pushbutton on each station. C. Turn each Mode Selector switch to Reset to make sure the stations are homed. D. Turn each Mode Selector switch to Auto mode. E. Place a part in the start position on the first station, if necessary. F. Press and release the Start pushbutton on each station. You should see the sequence start over and run until complete. 19. Repeat Steps 17 and 18 using the Emergency Stop pushbutton on each station to verify they all perform an E-Stop on the entire system. 20. Click the Monitor button to go offline from the processor you are currently working on. 21. Print out a copy of both of your ladder logic programs and place them in your portfolio. They will be used in your assessment. 21. Perform the following substeps to shut down the stations. A. Close the LAD/STL/FBD Editor on the PC. B. Close the SIMATIC Manager on the PC. D. Turn off the PC and monitor. E. Turn each station s Main Power switch to Off. F. Perform a lockout/tagout on each station s electrical power source. G. Perform a lockout/tagout on each station s pneumatic power source. B72001-AA10UEN MULTIPLE CONTROL 44

45 START START HALT CYCLE OUTPUT POWER RESET PRODUCTION COUNT EMERGENCY POWER ON OFF START RESET OUTPUT POWER EMERGENCY POWER ON OFF START RESET OUTPUT POWER EMERGENCY POWER ON OFF OBJECTIVE 8 DESCRIBE THE OPERATION OF A PLC PROGRAM THAT USES DISCRETE I/O HANDSHAKING FOR MULTIPLE RESET Often, when a part in process jams, a piece of equipment faults, or the emergency stop is used, the entire line has to be reset before the process can be restarted. Many companies include a master reset switch on a control panel to reset all stations at the same time. Generally, this control panel receives feedback from each station and will not enable the master start if any station is not reset CONTROLS RESET SIGNAL RESET SIGNAL CONTROLS RESET Figure 37. Master Reset Switch B72001-AA10UEN MULTIPLE CONTROL 45

46 The multiple station reset is operated through handshaking lines. A master reset signal would use a handshaking output from the master control panel, triggered by its reset switch. Because either this signal or the reset switch on each subsequent station will reset that station the handshaking bit would be in parallel with the reset switch signal. It does not replace the reset signal in the reset rung, as there may be instances where the reset switch is needed to reset the individual machine. It is important to verify that each station has been stopped prior to initiating the master reset. Figure 38 shows how turning the reset switch on the master control panel to reset turns on the master reset handshaking output to the station. This turns on the station s master reset handshaking input, which initiates the station s reset sequence. The handshake input will also turn on the master reset handshake output to pass the reset signal on to the next station. This process repeats until all of the stations are reset. RESET CONTROL PANEL ON 1 ìmaster Reset Switchî "Master Reset Handshake to Station" RESET RUNG 1 RESET SWITCH TURNS ON RESET OUTOUT TO ìreset" ìlift Cylinder Retract Bitî ìmaster Reset Handshake From Master Control Panelî ìlift Cylinder Retractî ìreset Slide Bitî RESET INPUT BIT IS PARALLEL TO THE RESET RESET TO NEXT ìmaster Reset Handshake From Master Control Panelî "Master Reset Handshake To Next Station" RESET SIGNAL SENT TO NEXT Figure 38. Master Reset Programming Example B72001-AA10UEN MULTIPLE CONTROL 46

47 SKILL 5 DESIGN A PLC PROGRAM TO USE DISCRETE I/O HANDSHAKING FOR A MULTIPLE RESET Procedure Overview In this procedure, you will modify your programs from the previous skill to provide a multiple station reset function. This will enable you to reset the whole system from the first station. 1. Locate the mechatronics system. 2. Verify two of the stations are fastened together and air and power lines are connected. If they are not, connect them. 3. Locate your programs for the stations that you modified in the last skill. You will modify these programs to enable a master reset function. 4. Modify each PLC program so that the Reset mode on the first station will reset both of the stations at the end of their sequence. The Start pushbuttons on each station will begin a new sequence. You may also want to place your halt logic back into each station so that the stop pushbutton works. The multiple station reset will use the same I/O used for the master cycle stop in the last skill. The individual programs should still operate as before, but with the master reset function rather than with the master cycle stop. B72001-AA10UEN MULTIPLE CONTROL 47

48 I/O DIAGRAM OUTPUT POWER ENABLED I0.3 HANDSHAKE 1 PREVIOUS I0.4 HANDSHAKE 2 PREVIOUS I0.5 HANDSHAKE 1 NEXT I0.6 Q4.1 Q4.2 Q4.3 Q4.4 HANDSHAKE 1 TO PREVIOUS HANDSHAKE 2 TO PREVIOUS HANDSHAKE 1 TO NEXT HANDSHAKE 2 TO NEXT HANDSHAKE 2 NEXT I0.7 RESET FROM PREVIOUS RESET TO NEXT Figure 39. I/O Diagram for Multiple Station Reset 5. Perform the following substeps to open the PLC programming software. A. Make sure that the interface from the personal computer to the PLC is connected. B. Power up the PC and monitor. C. Start the SIMATIC Manager. 6. Perform the following substeps to create a project. A. Open the project that you are going to edit. B. Save the Project as L10S5STAXXXX. This is Lap 10, Skill 5. Replace the X s with the station you are working on, followed by your initials. C. Enter your edits that you developed in Step 4. D. Save your project. 7. Repeat Step 6 for the other station. B72001-AA10UEN MULTIPLE CONTROL 48

49 8. Perform the following safety check before you begin working on the system. Make sure that you can answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Remove all obstructions from the work area Check for signs of damage to the equipment Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc. Tie up long hair Remove any robot teach pendants from the work area Locate the emergency stop button Ensure that safety glasses are worn by people in the area Ensure that all people are outside any work envelopes Figure 40. Mechatronics Safety Check 9. Connect an air supply line to the first station s air manifold quick connect. 10. Plug the first station s power cable into a power outlet. 11. Perform the following substeps to power up the stations. A. Place the Mode selector switches in the Manual position. B. Remove the lockout/tagout devices from the electrical power sources. C. Remove the lockout/tagout devices from the pneumatic power sources. D. Turn on air to the stations by shifting the levers on the lockout valves. E. Set the stations air supply regulators according to the following chart. AIR SUPPLY SETTINGS Station Main Regulator Auxiliary Regulator 87-MS1 50 psi/345 kpa 40 psi/276 kpa 87-MS2 50 psi/345 kpa 87-MS3 50 psi/345 kpa 87-MS4 50 psi/345 kpa 87-MS5 50 psi/345 kpa 12 psi/83 kpa 87-MS6 50 psi/345 kpa 87-MS7 50 psi/345 kpa Figure 41. Station Air Supply Settings F. Turn the stations Main Power switch to the On position. B72001-AA10UEN MULTIPLE CONTROL 49

50 12. Perform the following substeps to download the project to the PLC. A. Place the PLC power supply switch in the On position. B. Place the Mode Selector switch in the Run position. C. Reset the PLC. D. Download the SIMATIC 300 Station object for that station to the PLC. Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart. E. Click Yes on the dialog to complete a warm restart. 13. Repeat Step 12 for the other station. Note that you do have to connect the cable to the other PLCs to download the projects to them. 14. Go online with one of the processors and monitor that project. 15. Press the Output Power pushbutton on each station to enable the PLCs outputs. 16. Perform the following substeps to test the operation of the program. A. Turn Mode Selector switch on the first station to Reset. You should see each station reset their actuators to the home positions. B. Stock all feeders. C. Turn each Mode Selector switch to Auto mode. The Start pushbutton lights should be off at this time. If any of the lights are blinking, something is not reset or a feeder is empty. D. Press and release the Start pushbutton on each station. The system should run through the complete operation. E. Run three complete sequences through every station to verify the system operates correctly. F. Once the first station starts running the next sequence press the Emergency Stop pushbutton to stop both of the stations. You should observe all stations stop. The E-Stop lights should be blinking and the Start pushbutton active lamps are off. The Output Power on each station should also be off. G. Pull out the Emergency Stop pushbutton. The E-Stop pushbutton lights should be off, but the stations should still be stopped. H. Remove any parts on work surfaces on in grippers. I. Press the Output Power pushbutton on each station. B72001-AA10UEN MULTIPLE CONTROL 50

51 J. Turn each Mode Selector switch on the first station to Reset. The stations should all go to their home positions. K. Turn the first station s Mode Selector switch to Auto mode. The other station should still be in Auto mode. L. Verify the feeders are stocked with parts. M. Press and release the Start pushbutton on each station. You should observe all stations start a new sequence when a part is ready and continue to run until out of parts. 17. Click the Monitor button to go offline from the processor you are currently working on. 18. Print out a copy of both of your ladder logic programs and place them in your portfolio. They will be used in your assessment. 19. Perform the following substeps to shut down the stations. A. Close the LAD/STL/FBD Editor on the PC. B. Close the SIMATIC Manager on the PC. C. Turn off the PC and monitor. D. Turn each station s Main Power switch to Off. E. Perform a lockout/tagout on each station s electrical power source. F. Perform a lockout/tagout on each station s pneumatic power source. B72001-AA10UEN MULTIPLE CONTROL 51

52 SEGMENT 3 SELF REVIEW 1. The National Fire Protection Association s standard 79 states that emergency stop pushbuttons must be located at each and at other locations where an emergency stop is required. 2. Safety PLC s use separate for the safety portion of the controls. 3. Multiple station cycle stop allows for an of a manufacturing line. 4. The multiple station cycle stop signal is placed with the station s stop pushbutton signal. 5. Typically a part jam, equipment fault, or use of an requires that all of the stations get reset before the process can be restarted. 6. A master reset signal is used to the station s reset signal in the station PLC logic. B72001-AA10UEN MULTIPLE CONTROL 52

53 SEGMENT 4 FMS PROGRAMMING OBJECTIVE 9 DESCRIBE THE OPERATION OF A PLC PROGRAM THAT USES DISCRETE I/O HANDSHAKING FOR MULTIPLE FMS An FMS is a group of automated machines linked by a material handling system and a controller that can be programmed to make a variety of products, product styles, or parts. A multiple station FMS can use handshaking to alter functions at one or more stations to manufacture variations to a base product. This allows the same manufacturing process to make products that are customized to customers needs. BEARING INSERT ROTOR ASSEMBLY REAR HOUSING ASSEMBLY SCREW FASTENING VIBRATION BOWL FEEDER #2 #3 #4 #5 #1 PLC CELL CONTROL FINISHED PRODUCT FEED BASE HOUSING FEED Figure 42. Multiple Station FMS B72001-AA10UEN MULTIPLE CONTROL 53

54 For example, a manufacturer of directional control valves could have six options: acrylic or aluminum body, 3 or 4-way valve spool, and a spring return or detent. When the order is placed, certain bits are set to specify which option to select at each assembly process. Figure 43. Directional Control Valve B72001-AA10UEN MULTIPLE CONTROL 54