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Plagemann IPC recipe book

IPC recipe book
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Blue Digest
Blue Digest
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Plagemann
IPC recipe book

Control
Electronics
Plagemann
IPC recipe book
Blue Digest
on Automation
Blue Digest on Automation
© 2004 by Festo AG & Co.

Ruiter Strasse 82
D-73734 Esslingen
Federal Republic of Germany
Tel. (0711) 347-0
Fax. (0711) 347-2155
All texts, representations, illustrations and drawings included in this book are the
intellectual property of Festo AG & Co., and are protected by copyright law. All rights
reserved, including translation rights. No part of this publication may be reproduced or
transmitted in any form or by any means, electronic, mechanical, photocopying or
otherwise, without the prior written permission of Festo AG & Co.
A few years ago it was still a topic of discussion as to whether industrial PCs and
Preface programmable logic controllers were in competition with each other or were
complementary. Today, both systems have their place and are used as a matter of
course.
The focus of discussion and development has now shifted towards network technology
instead. Decentralized automation technology is once again the hot topic in
automation. The Ethernet network – an age-old fixture in the PC world but entirely new
in the field of automation – has made decentralized automation manageable. The use
of fieldbusses for decentralizing the input/output level has led to experts in automation
technology becoming familiar with the terminology and techniques of networking and
serial data transmission. This knowledge is now being combined with the experience
of the network engineers. As a result, integrating automation technology into the
networks used in manufacturing and administration is at last becoming so easy that the
technology can be put to widespread use.
For almost two decades now, Beck IPC GmbH, a subsidiary of Festo AG & Co, has
been developing industrial control technology based on PC technology. In order to
make the grade, every new development has had to meet certain requirements. Each
one must be:
_ small and maintenance-free, to allow smaller control cabinets to be used

_ PC-based, to enable users to respond flexibly to widely differing demands
_ modular and/or part of a complete family of hardware and software
_ programmable as a PC or a PLC
_ network-capable with Ethernet
This book describes examples of applications using the controllers from Beck and
Festo. We trust you enjoy browsing and reading through the book, and hope that the
descriptions might give you some ideas for new solutions of your own.
Wetzlar, October 15, 2000

Bernhard Plagemann
b.plagemann@beck-ipc.com
http://www.beck-ipc.com
http://www.festo.com
Preface..............................................................................................................................5
Contents
Control and handling technology ..............................................................................9
The Boxer opens cardboard boxes..................................................................................10
From a handling device to a gateway..............................................................................12
Fully automatic welding in giant containers....................................................................14
Feeding, checking and sorting small parts with the Checkbox ......................................16
Making beautiful clothes in Denmark ..............................................................................18
Storing grain .....................................................................................................................20
Controlling mobile road tarring machines ........................................................................21
Sending electronic devices from the clean room for testing ...........................................22
Manufacture of MKP-SI capacitors ..................................................................................24
Production of spray cans .................................................................................................26
Sawing up thick tree trunks..............................................................................................28
Controlling at random .......................................................................................................30
Excursion: Programming with FST...............................................................................32
Networking and remote maintenance ......................................................................35

Pad printing on a network................................................................................................36
Securing pedestrian precincts .........................................................................................38
Recording process data and arranging for essential repairs ...........................................40
Data backup on the network.............................................................................................42
Modernisation of a high-bay warehouse ..........................................................................44
Calling the emergency repair service ..............................................................................45
Calling the machine .........................................................................................................46
Control and operation via the Internet ..............................................................................47
Excursion: Programming in line with IEC 6 1131-3 with MULTIPROG........................48
Measurement technology, data processing and quality assurance..................51

Collecting and processing environmental data ...............................................................52
Observation of historical buildings and structures..........................................................54
Compressed-air filling station for tyres ............................................................................56
Automated soil examination ............................................................................................57
Testing Tipptronic system modules................................................................................58
Testing Checkbox modules.............................................................................................60
Monitoring welding data ...................................................................................................62
Optimisation of a gas-fired power station ........................................................................63
Quality assurance in cylinder manufacture.....................................................................64
Acquisition of measured data and controlling an aerial
in a measuring balloon.....................................................................................................65
Examination of rubber compounds ..................................................................................66
Testing CAN valves.........................................................................................................68
Measuring soot content in the air.....................................................................................70
Monitoring a radio station's high-frequency band ............................................................71
Excursion: Programming in C/C++................................................................................72
Process control systems, lab. technology and hydr. engineering...................73
Water treatment ................................................................................................................74
Ensuring cleanliness in cheese production ....................................................................79
Statistical process control in the manufacture of thermocylinders .................................80
Data acquisition in sewage treatment plants...................................................................81
Controlling a biological trickling filter scrubber ...............................................................82
Determining the cell state of microorganisms ................................................................84
Filling up with liquefied natural gas.................................................................................86
Providing for clean water..................................................................................................88
Edutainment and simulation.......................................................................................91

Discoveries on the high seas ..........................................................................................92
Keepers in the wild...........................................................................................................94
Learning to use modern automation technology..............................................................95
Applications with the IPC@CHIP ................................................................................97

Ethernet - CAN gateway ...................................................................................................98
Controlling with the IPC@CHIP........................................................................................99
Learning with the IPC@CHIP .........................................................................................100
Monitoring with the IPC@CHIP ......................................................................................101
Excursion: Hardware ...................................................................................................102
Index..............................................................................................................................105
It is certainly a pleasure to fold open a cardboard box and lovingly to pack it with
Control and handling carefully chosen Christmas presents for someone close to your heart.
technology
It is hard, tiring work to open not one cardboard box but
several hundred a day so that they can be filled with goods. This is where a
combination of mechanical systems and control technology is called for. This is where
pneumatic components are used for the drive units, in conjunction with small, fast-
acting controllers.
Starting from "little" tasks such as these right through to assembly stations, they are
still out there today: systems and installations which need control technology, using
Boolean algebra, AND and OR, steps for organising the working sequence – all this
helps get the job done. Even if public discussion tends more to focus on the networks,
the operating philosophy and many other things, there are still millions of relays
switching motors on and off, and millions of valves letting cylinders travel back and
forth.
The modular system of the IPC PS1 with its multiplicity of different input and output
modules and the modules for controlling stepping motors, servoelectric and
servopneumatic axes is ideally suited to mastering these tasks. And the mini
controllers of the Front End Controller family feel most at home in small-scale
applications, where there is always call for fast and flexible automation technology that
boosts productivity.
In this section you will find a number of examples in which the main focus is on control
technology. Enjoy your read.
Control and handling technology 9

As explained in the introduction to this section, folding open hundreds of cardboard
The Boxer opens boxes is laborious and tedious work. All the same, every day more and more boxes
cardboard boxes have to be opened, taped, filled, closed, addressed … Mail-order business is growing –
and every time an order is placed, a new box is needed.
Automating a task like this calls for a great deal of know-how. Because although
cardboard boxes are sturdy, they are certainly not stiff. The box gives way, moves, is
never precisely the same size, and appears in an infinite number of variants. With the
aid of a sophisticated mechanical system in conjunction with pneumatic drives and
vacuum suction devices, boxes of different sizes and different strengths can be opened
and set up automatically, and the base taped ready for the box to be filled.
The Boxer from the Rembrandt Packaging company in

Holland is one such device that assembles not just one but hundreds of cardboard
boxes a day, and also tapes up the base. The boxes can then be filled, sealed and
dispatched.
As easy as it may sound to "open a cardboard box", the solution is equally elaborate
and complex. This is because a system has to be constructed that is very cost-
effective (cardboard boxes should of course cost nothing – they are "only" the
packaging) yet at the same time highly flexible. Depending on the products being
packed, the boxes have to be larger or smaller, thicker or thinner walled, stiffer or more
pliable. Not only that, no-one really has space for a Boxer, so the machine must be
compact and offer very flexible installation options – for operation from the left or the
right, or any other variant you care to think of. Rembrandt has therefore constructed the
Boxer from individual modules which can be assembled to suit the customer's specific
requirements.
Cooperation between Festo and Rembrandt has helped to make the Boxer flexible and
fast in production. Festo in Holland manufactures the entire control cabinet with the
10 Control and handling technology

controller, valve terminals and all connecting cables and connection tubes. The cables
and tubes are supplied by Festo ready cut to the correct length. The controller is fully
programmed and tested. When the control cabinet is delivered, the assembly team at
Rembrandt needs just another two hours to place the Boxer at the company's disposal,
ready installed and tested. The only thing that is faster is assembling the cardboard
boxes with the Boxer ...
Hardware IPC FEC FC20 Mini controller with flash memory for the application.
Software FST With FST a system of this type can be programmed in double-quick time,
because the process being controlled is a sequence of movements which are
ideal for programming with the STEP command in FST.
Keywords Packaging technology, cardboard box, sequence control

Handling devices, being special-purpose robots, are always tied to a particular type of
From a handling machine. Nevertheless, they must be designed in such a way that they can be adapted
device to a gateway to a range of different machine variants. As far as controlling a handling device is
concerned, this means that for example the stroke lengths, slewing angles of the shafts
and interlocking times have to be adjustable. Simple handling devices have often
developed into complex process interfaces or gateways, which in addition to their
handling functions also have roles to play in production data acquisition and
networking. This is an area where using an industrial PC is very much the obvious
choice.
A major German manufacturer of handling devices for injection moulding machines

was also faced with this task, because the family of devices covers precisely this
range from simple gantry robots to process interfaces. The company decided to go for
the PS1 system across the board. Not only does this make stockkeeping easier, it also
means that staff training can be limited to one type of control electronics. One reason
why this decision also has a positive effect on development times is that the system is
very simple to program, like a PLC. This can be illustrated using the example of a
sprue removal device.
Sprue removal device
The device can be mounted on any injection moulding machine. After the injection
process, the device takes hold of the sprue part in the area of the opened mould and
transfers it to a container. The injection moulded part itself is separated automatically
from the sprue and drops into a different container. Within the production process, the
removal operation not only represents an unproductive length of time, it is also linked
to energy loss, because the open mould quickly cools down. The shorter the time
taken for removal, the lower the energy loss and the more productive the plant is in
operation. The electronics hardware can meet this requirement without any difficulty.
The challenge in this case is for the pneumatic components. But the control program,

too, has to take account of this. It must not be permitted to operate with generously
dimensioned waiting times.
The key components of the handling system are the following:
_ The x-axis, which runs parallel to the ejector on the injection moulding machine. It
is implemented with two short-stroke pneumatic cylinders which allow a maximum
travel of 50 mm.
_ The y-axis is arranged perpendicular to the ejection system; a pneumatic linear

drive with a maximum stroke of 500 mm was used for this. The z-axis is in the form
of a rotation axis with a slewing angle of 90°. The gripping tool is a pair of tongs
mounted on one end of the y-axis cylinder. All of the axis cylinders and the tongs
are driven via 5/2-way valves.
The requirements that need to be met by the control system of an arrangement of this
nature are satisfied by the PS1 system in the best possible way. All control tasks can
be mastered with the central processing unit and the digital input/output options. As
well as this, the IPC fits into the gap in the switchbox which all of the other components
leave free.
Program language One fundamental prerequisite for the choice of hardware was simple programmability.
The FST software makes the programming of step-by-step sequences easier thanks to
the STEP operation and the ability to easily administer up to 64 different
programs/tasks. The control program is modular and therefore its structure means it is
easy to maintain. The plant functions are implemented in two modules: the key
interrogation part establishes the connection to the operating personnel, while control of
the handling components is dealt with in the main program. The FST programming
software supports step control in that the steps are managed by the system and the
programmer is relieved of the task of setting up a step variable and interrogating it.
Hardware BP11 3-slot busboard

HC16-F PC/CHIP CPU with FST kernel
IM10 16-bit digital input module
OM10 16-bit digital output module
Of the 16 digital output signals which the OM10 module makes available, 4 are used to
send commands to the injection moulding machine (ejector, mould closure and core
puller).
Keywords Handling system, injection moulding, step programming, positioning

Huge storage containers are used for storing foodstuffs, grain, chemicals, viscose – in
Fully automatic fact raw materials of a great variety of types. That is nothing unusual. But the larger
welding in giant these containers are, the more expensive and difficult they are to build and, later, to
containers repair or replace as necessary. And it is here, in the repair or complete overhaul of such
containers, that the Swedish company Uddcomb comes into its own. They have
developed a procedure by means of which existing containers which have become
brittle or have developed a leak are lined from the inside with a new steel container.
This sounds very simple, because it is a kind of pot in a pot. Actually carrying this out,
though, is not so easy, because the new internal container cannot simply be inserted
inside the old one. No, it has to be welded together from individual metal plates inside
the container. This is the only way of ensuring that the new internal container is
precisely matched to the existing container.
In principle, the yards and yards of seams can also be welded by hand, but in most
cases this would make complete renewal uneconomic. Uddcomb has developed a
welding machine which automatically moves along the welds inside the container in a
suspended position. The welding machine is moved with the aid of stepping motors,
and the welding current is used as a measure of the correct distance for the welding
wire.
The control system needed for such an unusual welding machine has to be extremely
flexible. As well as this it should be small, because the entire system is forever having
to be transported from place to place. The containers that need to be repaired do not
come to Uddcomb, instead the refurbishment team always has to travel to wherever

there is another container waiting for a new interior lining. Being constantly on the road
is not the normal operational situation for a machine control system. With the IPC PS1,
this works.
Hardware BP50 5-slot busboard with power supply

HC16-F PC/CHIP CPU, EPROM, RAM, flash
2 x AM11 Stepping motor module
IO10 8 x analog input module
OM21 Digital input/output module each 8-bit
Software FST was chosen as the programming language; it is simple and quickly adaptable,
supports the positioning task and is very well known to the people putting the project
into practice.
Keywords Welding, stepping motor, positioning, mobile application

Feeding small parts such as screws, rings, springs, perfume bottles, nuts, toothbrush
Feeding, checking and heads and a myriad of other parts in the proper orientation is an age-old problem in
sorting small parts automated production. There are countless applications that use shaker conveyors,
with the Checkbox which have all sorts of elaborate mechanical "chicanery" to make sure that the parts
are always fed in precisely the orientation required by the next stage of production.
The Checkbox takes a new approach. In this case, no mechanical obstacles are used
but instead a camera is used to check the orientation. In a teach-in process, the control
system is taught what the "correct" part should look like. The computer compares the
captured image with the stored image and issues a command to blow out or eject those
parts that are not positioned correctly.
The particular advantage of this method is that the Checkbox is highly flexible in use.
The teach-in process takes a matter of a few minutes. The correctly oriented part has to
be passed beneath the camera several times, the computer saves the image – that's
all. In contrast, setting up a mechanical obstacle course can be a matter of hours or
sometimes even days.
The second advantage of the Checkbox is that not only can the parts be checked that
they are fed in the proper orientation, they can also be examined for entirely different
properties, such as their shape, colour, material etc. In this way, the Checkbox can
also be used for sorting, not only feeding.

The centrepiece of the Checkbox is the camera and its associated image processor.
The image processor has been developed by the Checkbox team, and in technical
terms is quite a gem. This is because with the Checkbox, as is always the case in
automated production, what matters is speed: thousands of parts per minute are
supposed to pass through the system. This is only possible if the CPU is designed
exclusively for the purpose of image processing (image capture, image comparison)
and the response to evaluation of the image. The Checkbox team used the IPC PS1
Professional as the basis for its design. The busboard and the input/output modules
are original PS1 components, while the CPU is a Checkbox development.
Hardware Example configuration

BP50 5-slot busboard with power supply
OM21 Input/output module each 8-bit
Checkbox image processor
Software C/C++ is the right programming language for a task such as this.
Keywords Image processing, shaker, Checkbox

Brandtex A/S was founded in Denmark in 1935, and is today one of the largest textile
Making beautiful companies in Scandinavia. The various subsidiaries of the Brandtex group produce all
clothes in Denmark types of textiles, ranging from children's clothes, jeans, young fashion and swimwear to
knitwear and men's wear and ladies' wear. Around 2,000 staff are employed around the
world in the design, production and sale of textiles.
Particularly in the textile sector, international competition is extremely tough. For a

company based in Europe, impeccable automation technology is vitally necessary in
order to be able to sell textiles in accordance with market conditions: in this case this
means on the one hand offering value for money, but much more than this, being
flexible. Setting fashion trends means offering high-quality designs and converting
them very quickly into real products. Following fashion trends means converting the
standards set by fashion into products in double-quick time.
It is at this interface between fashion and automation technology that Brandtex and
Festo come together. Recently Brandtex began operation with a new generation of
automatic sewing machines, for sewing trousers and skirts. The installation is
controlled by an IPC PS1.
Of course it is not a problem to build automatic sewing

machines. These are available in a great variety of designs and versions. As far as
Brandtex was concerned, it was not simply a matter of a sewing machine but rather of
high performance in conjunction with low investment optimised for the task in hand.
The control system to be used as well as the chosen pneumatics therefore also had to
be subjected to the dictates of rigorous cost control. A number of components played
their part in keeping the costs of the sewing machine down.
Firstly there is the activation of the positioning system required for the sewing process.
The power section for a stepping motor is activated directly from the inputs/outputs of
the CPU. All of the parameters for the stepping motor, such as the position, speed,
starting ramp and brake ramp etc., are entered in a module in the FST software. The
outputs specify the frequency and direction for the stepping motor directly. The inputs
read directly from the sensors on the shaft. There is no need for a separate stepping
motor controller.
Then there is the CPU and the entire IPC PS1 system. The HC01 CPU is specifically
designed for small- to medium-sized autonomous plants, and in terms of its price fits
very well into a project as critical as this.
Thirdly there is the programming software that is used. With the FST software, the
programming process is adapted to the way that the engineers think.

Fourthly we come to the Festo valve terminals used in this system, which enable the
pneumatic power section to be activated quickly and easily, and are also extremely
compact.
One particularly important factor regarding the use of an automatic sewing machine is
also that the operating personnel do not usually have much idea of electronics or
computers. The necessary operator actions must therefore be kept simple, clear and
uncomplicated. At Brandtex they use an EXOR terminal for the purpose of operator
control. This terminal is itself equipped with a computer, so it can access the control
system independently. Clear and uncluttered software allows the data and
communication rules to be entered in the simplest possible way.

PS10 Power supply unit
HC01 CPU with 8 bidirectional I/Os
2 x IM11 16-bit digital inputs
2 x OM11 16-bit digital outputs
Keywords HC01, positioning, stepping motor, EXOR display, valve terminals, FST, textile
industry

When Grandmother tells stories of how the barley used to be harvested and stored, old
Storing grain memories are aroused and a picture is painted of manual farming in a natural idyll.
When the grain harvested today's agricultural reality is
put in central storage in order to be able to supply a major city with flour for an entire
year, what is needed are huge silos which can be filled and emptied fully
automatically. In Australia there is an industrial park comprising silos, conveyor belts,
grain hoists and access roads for the trucks bringing or fetching the grain. The system
includes a total of 16 silos, two hoists and 6 conveyor belts, and depending on
requirements it has to be persuaded to put grain in storage, release it from stock,
relocate the valuable goods within the system or carry out a number of similar tasks.
Festo Australia has used an IPC PS1 Professional for this purpose, which can be
operated in its entirety from two locations with the aid of EXOR ECT touch panels. On
either of these two panels the operator can enter whether grain is to be stored, relocated
or released, and from where to where this is to be done. The precise route through the
labyrinth of conveyors and containers is found by the control system itself.
Two jobs can be processed simultaneously, so it is impossible for the two operators
working at the panels to get in each other's way.
On its route through the containers, the grain is steered with pneumatic cylinders which
report back their position to the control system with the aid of an integrated
displacement measurement facility. The speed with which the grain flows is controlled
by the opening angle of the gates. The valves for triggering the pneumatics are grouped
on three sets of Festo valve terminals, which in turn are connected to the control
system via the Festo fieldbus. This has the effect of considerably reducing the cost of
installing the system.

CP30 RS232c interface
CP61 Festo fieldbus master
3 x IM10 16-bit digital input module
3 x OM10 16-bit digital output module
3 x IO12 8 x analog input module
3 x IFB1 03 Type III valve terminals with Festo fieldbus node
2 x ECT-16 EXOR touch display
Software The programming makes use of the multitasking system provided by the FST software
and, in addition, the MultiCI driver, which ensures that the touch panels have direct
access to all variables in the control system.
Keywords Agriculture, silo, pneumatic cylinder position detection, touch panel

In the fully automatic high-performance road tarring machines that are used around the
Controlling mobile world, machines which can lay up to 90m of asphalt per minute, a rugged control
road tarring machines system is needed in order to perform a varied set of tasks.
These include:
_ Controlling every aspect of the vehicle hydraulics
_ Operator prompting via a graphics monitor for the driver
_ On larger vehicles, networking via a CAN fieldbus to the control console for the
tarring machine operator.
_ On special vehicles, networking to a hand-held terminal for personnel
accompanying the vehicle on foot
_ Complete recipe management and control of the mixtures of tar, chippings and
colouring
The complexity of the tasks calls for programming in a high-level language – in this
example it is in C – in a modular system environment.
The IPC PS1 is particularly well suited to this application. It is compact, robust,
modular and therefore flexible, programmable in a high-level language, and the special
modules are based on an open standard.
A remote maintenance facility via GSM modem has been included on many vehicles.
Configuration example for a small vehicle:

HC16 PC/CHIP CPU, EPROM, RAM, flash
2 x IO60 4 x analog output module
Optional CAN interface
Software Programming in C
Keywords Road tarring machines, vehicle hydraulics, operator prompting, CAN, C/C++, GSM
modem, remote maintenance

The production of hard disks, floppy disks, CD ROM drives or else are a minor
Sending electronic technical miracle. For a long time now we have got used to the idea that the mass
devices from the clean storage devices in our PCs do their job year after year. And yet each of these devices
room for testing is a masterpiece of mechanical precision and miniaturisation. During operation, for
example, the clearance between the read-write heads of a hard disk and the disk is only
a few micrometers, far less than for instance the thickness of a human hair. Awareness
of this fact alone should make it plain that production of such devices themselves have
to take place in a clean room, to ensure that under no circumstances can dust, dirt or
any other foreign matter be allowed to enter the device.
On the other hand, eventually any part produced will have to leave the clean room,
because the office where the computer will be expected to do its stuff for the customer
really cannot be called a clean room.
Product ion o f
mass s torage devices
Pick & Place Unit s

PP1 ... PP8
Clean Room
Further production
Pick & Place Unit s
PP1 ... PP8
Points Point s Poin ts
Tes t Tes t Test
For reasons of cost-saving, if no other, the clean room has to be kept as small as
possible. As many production stages as possible, therefore, should take place outside
the clean room.
One of the major manufacturers for mass storage devices produces hard disks in many
Asian countries. Festo in collaboration with an engineering company has contributed to
achieving a further automation of hard disk manufacture, and thus making it even more
productive.
This involved setting up fully automatic pick-and-place units at the end of the clean
room production process; these transfer the finished disks onto a conveyor system
which leaves the area of the clean room. On the opposite side, now under largely
normal ambient conditions, the disks are turned over, identified by barcode readers and
sent to a testing station according to type.
On first impression, that sounds nothing special: transfer – transport – transfer –

transport – distribute. One special feature of this application was that the automatic

system had to be integrated fully into an existing production facility that was previously
operated by hand. The traditional procedure was for the disks to be placed on stainless
steel trolleys in the clean room; these trolleys were then rolled out of the clean room,
and in the testing area the disks were taken out of the trolleys again by hand and given
over to testing, sorted according to type. It is also worth noting that the pick-and-place
devices work on one side, inside the clean room. The entire pneumatic system
therefore had to be designed in such a way as not to cause contamination in the clean
room. Secondly, we can assume that the disks are not produced in a leisurely manner
one after the other, but thousands of disks every day. The equipment list for merely the
first of three project stages is correspondingly extensive: 26 IPC PS1 Professional
modules were installed, 52 pick-and-place units with HMP cylinders, 180 type CPV
pneumatic valve terminals, and a great deal more besides.
The IPC PS1s for the pick-and-place units are equipped with Profibus DP master
modules. The systems at the sorting gates have HC02 CPUs and digital I/O modules.
All systems are fitted with Ethernet interfaces and are networked with a central PC. A
Visual Basic program written especially for this application runs on this PC, monitoring
all of the connected stations and issuing error messages in plain text. Among other
things, these messages are based on the fact that all cylinder movements are
monitored by a timeout feature.
Hardware The pick-and-place units consist of the following:

BP 31 8-slot busboard
PS 10 Power supply unit
CP 14 Ethernet interface
CP 62 Profibus DP master
IM 11 16 x digital input module
OM11 16 x digital output module
2xCP 35 Serial interface
The sorting gate controllers consist of:

BP 31 8-slot busboard
PS 10 Power supply unit
HC02-F AM186 CPU, flash, Ethernet
IM 11 16 x digital input module
OM11 16 x digital output module
2xCP 35 Serial interface
Software All control programs are written in FST, the monitoring PC program is written in Visual
Basic.
Keywords Clean room, pick-and-place, handling, Visual Basic, Profibus DP, Ethernet

Metallised plastic polypropylene safety capacitors are capacitors that are made up of
Manufacture of MKP-SI several thousand winding layers. The capacitor elements are packed in oil in a metal
capacitors housing. The housing has a type of expansion joint to enable it to expand if the
capacitor undergoes thermal expansion as a result of overload or a fault. The "SI" in the
name MKP-SI capacitor refers to the property that one of the capacitor's connecting
wires has a predefined break point. The connecting wire is attached in such a way that
if the housing expands the wire is subjected to tension. The wire breaks at the
predefined break point; in the event of a fault, therefore, the capacitor is electrically
isolated and therefore harmless.
The application described here is not responsible for the entire capacitor production
process, "only" for the attachment of the connecting wires including the predefined
break point. As is usually the case nowadays in automation technology, the primary
demands made of the system were flexibility and speed while maintaining constant
quality.
_ Flexibility means that around 100 types of capacitor have to be produced, each with
different dimensions. And flexibility in this case also means that additional type
data can be added on-line at any time. A small database administers all geometric
data applicable to the various types so that the machine is always prepared for
every job that comes along.
_ Speed means that a cycle time of less than 8 seconds per capacitor has to be
maintained.
_ Quality means that, along with technical functionality, the consideration of safety
plays a very important part. The predefined break point in the connecting wire is a
safety feature that, when the capacitor is subsequently put to use, is responsible for
the safety of much larger systems and processes.
Hardware Plümer Elektrotechnik, a company based in Berlin, is responsible for the control
section. It chose the IPC PS1 Professional because it is sufficiently flexible to satisfy
the various requirements that the system has to meet in terms of control technology.
For the purposes of our example, this means:
BP40 14-slot busboard

HC12 PC/CHIP CPU, EPROM, RAM
CP50 InterBus master
4 x AM11 2 x stepping motor module, in this case for controlling 7 stepping motor
axles (Portescape motors with Nanotec power section)
PS1-IM10 16-bit digital input module

PS1-OM10 16-bit digital output module
PS1-DIS1 LCD display
PS1-FC/FD10 Floppy disk controller and drive, in this case as a boot drive and as
storage for the customer's type database.

Software Plümer Elektrotechnik decided on Pascal as the programming language for this
installation. The program is divided into two groups, which can never be executed
simultaneously. These are a real-time-capable control section with a cycle time of < 20
ms and use of the watchdog for monitoring run-time errors, and an operating and
parameterisation section without real-time capability which allows access to the type
database with the aid of the floppy disk drive.
A sophisticated error monitoring function monitors every step of the control technology
sequence. Every cylinder movement, for example, is monitored by a timer module. If
the movement does not occur within a specified time, an error message is displayed on
the DIS1 with indication of the cylinder, limit switch and valve. To the advantage of the
maintenance personnel, therefore, all standard errors that may occur in the control
technology are carefully monitored and are displayed in plain text. Short stoppage
times are the benefit of having a monitoring program as well-devised as this.
Keywords Capacitor manufacture, quality requirements, stepping motor, InterBus, Pascal,

database, error monitoring

The importance of spray cans in many people's day-to-day life is huge. Although they
Production of spray are very rarely spoken about, their possible uses and the areas in which they are used
cans are so varied that it is likely to be very difficult to exclude any everyday field of use.
The most common contents of spray cans are cleaning agents, lubricants, oils, paints
etc., which are then available for easy and convenient use. Now that CFCs have been
replaced by compressed air and the can itself is usually made of recyclable metal, the
discussions surrounding environmental compatibility have largely subsided. It is just
that someone has to make the cans. And this is where the PS1 system helps.
The tube in the can Most spray cans are made in such a way that inside the can a plastic tube is attached
to the valve, extending down to the base of the can. This ensures that, provided the can
is held upright, virtually all of the contents can be used. For many applications there is
also the possibility of attaching a tube to the outside of the valve, with the aid of which
the oil, cleaning agent or whatever else the can contains can be sprayed with great
accuracy exactly where it is needed. It is these tubes which have particularly grabbed
our attention.
Fast, faster, fastest These days, nothing carries on as usual in the old, easy-going way. Of course it is not
enough to cut a tube to length and put it in position. In the PS1-controlled plants, 650
tubes per minute are cut to length, the length is checked, and the tubes are attached
and are tested in position – that is one tube every 92 ms. The combination of
sophisticated mechanical engineering and well thought-out control technology makes
these speeds possible.
The company responsible for the mechanical
engineering side is Fischer in Bad Oldeslohe. A unit that from the outside looks like a
CNC machine processes the tube material, cuts it to different lengths as required and
inserts the tubes.
The company responsible for the control technology is Däter in Hamburg. Mr.
Peemöller has put together a system that is made up of two separate PS1 systems.

Hardware The control system consists of the following:
HC27 32-bit CPU
CP10 2 x RS232 module
Kobolt servocontroller and servoamplifier for the positioning system.
A separate CPU for operator guidance - the human-machine interface - is

accommodated on a second busboard:
HC16 PC/chip CPU, EPROM, RAM, flash
BG20 Display
The operator's station communicates with the control computer via an RS232c
interface.
Program language The entire system is programmed in MULTIPROG, the programming package that
conforms to IEC 6 1131-3.
Keywords Spray cans, cutting to length, positioning, testing, IEC 6 1131, MULTIPROG

Tree trunks: they can be thick or thin, hard or soft – that's how it is with tree trunks.
Sawing up thick tree Boards at a DIY store or at a timber merchant may be thick or thin, long or short, best
trunks quality or not so good. But if you want boards with a thickness of 18 mm, then they
should be precisely 18 mm thick, exactly like those you bought 6 weeks ago. Between
your DIY store with its boards that are always exactly 18 mm thick and the tree in the
forest there is a great deal of work. One of Europe's biggest manufacturers of band-saw
machines for sawmills is having its band saws equipped with the IPC PS1.
The tree trunks delivered to the sawmill need to be sawn into boards to a thickness that
precisely matches the details of the customers' orders. The demands imposed on
board production are not so very different from the demands made on the production of
items such as valves or alarm clocks: constant quality of the end product, even if the
primary product – the tree trunks – is highly variable; high flexibility, with batch sizes
alternating between just 1 and several hundred; and speed of production. Of course, the
primary product has to be handled quite differently from products such as small screws.
The huge trunks in some cases have diameters of over 1 metre. They are placed on
trucks that remind you of railway goods wagons. There they are clamped in place and
taken to the saw. There is no-one standing by the saw holding a metre rule to measure
what thickness the board should have: instead, positioning is carried out with high-
performance frequency-controlled three-phase motors and with hydraulic shafts. The
required thickness for each order is entered at a control console, the clamping trestles
on the truck clamp the trunk and guide it with an accuracy measured in millimetres to
the band saw – or to the double band saw, if a second, offset and separately
positionable band saw is also connected. The idler wheel on the band saw alone may
have a diameter of up to 1.8 m - while the IPC PS1, in contrast, is barely larger than one
or other of the fixing bolts.

Open- and closed-loop Clamping, starting, stopping, sawing etc. are all classical control tasks which can be
control with a CPU dealt with by any PLC. The positioning of what nowadays may be up to 6 axes, on the
other hand, requires a quite considerable level of computation work because the axes
have to be coordinated with each other. And user guidance, with entry of the job details,
log printing etc. is a typical task for a PC.
Hardware In the IPC PS1, all of these tasks are brought together. A single CPU takes care of
controlling, positioning and user guidance. Depending on the size of the saw machine,
12x or 20x busboards are used. Positioning is controlled with AM20 modules, and the
CPUs are usually 486s.
Software The software follows hot on the heels of the distribution of tasks: the control section is
programmed in S5. The S5 operating system is embedded in a multitasking kernel, so
the positioning and the user interface are written in C/C++. An ideal combination.
Because the tough sawmill environment requires a simple interface to the control
technology. And these days Step5 is also familiar to electricians at sawmills. User
prompting and positioning, on the other hand, are reserved for the PS1 engineer.
Keywords Sawmill, positioning, S5, C/C++

Can you imagine entrusting your application to chance, random events? Or even that it
Controlling at random is conceivable that it is the task of a controller to work "at random"? Well, there is such
an application.
In order to boost the sales of products that are packed in cans, sometimes surprise gifts
are included with them. A drinks manufacturer, for example, arranged to include
vouchers for lavish holiday trips in the tops of their drinks cans. A customer who buys
the can with the "golden nut" and actually finds the voucher and redeems it has won a
valuable prize.
The manufacturer of the drinks cans, or rather the manufacturer of the tops for the drinks
cans, therefore has to see to it that the vouchers – a prescribed number of vouchers in
each production batch – are included in the tops. And the inclusion of the special can
tops must be done at random.
To do this, a small station was developed which inserts the tops with vouchers into the
production process according to a random principle. The top itself is of course
functionally identical to every normal top, but it has that little something extra on board
...
The IPC PS1 that controls this random insertion machine has to be able to provide
precise information, however, on when tops have been inserted, how many are still left
to be inserted and so on and so forth.
Networking with the office
via Ethernet – every CPU In addition, the controller is integrated into the company's network, because the
can do that. "golden" tops should of course only be inserted if the customer actually requires this.
In collaboration with Festo Ireland, a manufacturer has

developed a machine of this type, connected the controller to the central database in
the company network and implemented local operator control and visualisation with an
EXOR display.

CP61 Festo fieldbus slave
CP14 Ethernet interface
Software The station is programmed in FST, because programming the automatic insertion
process is quickest in FST.
The dimensions of the tops differ depending on the production batch. The insertion arm
is therefore positioned with a servopneumatic regulator, the SPC200 from Festo.

The operating terminal is programmed with the EXOR designer software, which already
includes the driver for FST controllers and supports development on even complex and
sophisticated operating interfaces in the simplest possible way.
The system is networked with the company's local area network and the company
database via Ethernet. The Festo fieldbus slave is integrated into the system because
the production master computer has a Festo fieldbus master and as a result is able to
receive status messages from the station very easily.
Keywords Random generator, Festo fieldbus, Ethernet, SPC200, EXOR, positioning, database,
FST

For many years now, the proportion of software costs in automation projects as
Programming with compared with hardware costs has been rising almost continuously. Every new set of
FST programming software has to try and square the circle yet again, because the demands
made of good programming software are fundamentally contradictory:
_ Because hundreds of thousands of mini controllers control applications on a small

and even miniature scale, the software must be fast and easy to operate. For many
members of staff in project departments, creating a fully finished project every day
is an imperative. Complicated configuration routines would only interfere with the
process.
_ Because large projects, in particular, can quickly become confused and chaotic,
especially if they have to be constantly changed because of endless follow-up
requests, the software has to be powerful in order to support systems with
thousands of input/outputs and complex task structures.
_ The familiarisation time for beginners must be short – or really should not be
necessary at all. Everything must be self-explanatory, intuitive and simple.
No programming software manages this entirely. Compromises always have to be

made.
The FST software approaches these compromises from a highly original angle. It
allows programming to be performed in the way that you would describe a machine.
IF ... THEN "If a part is available here, then this cylinder should advance."
OTHRW This becomes:
IF part_present
THEN SET cylA_forward
This IF ... THEN ... OTHRW structure, so familiar to programmers in high-level

languages, in conjunction with the SET and RESET operations for activating and
deactivating a digital output, is so neat and easy to remember that the first lines of the
program can be written and understood very quickly even by beginners.
STEP What is more, because more than 80% of all machines represent a sequence control
system in automatic operation, the FST software supports the programming of such
sequences by operating independently. A typical automatic handling machine, for
example, has to guide the gripper through the following sequence:
- lower - close - raise - move - lower - open
The FST software uses the STEP operation for this purpose. This automatically forces
a program into a single step, the active one.

STEP Start
IF
THEN
STEP Lower
IF
THEN
STEP Close
As a result, sequences of this type lose their terrors and can be programmed in the
twinkling of an eye.
Multitasking Although the sequence is the central element for most machines, it is far from being the
largest part of the program. Setting up, manual operation, error messages, organisation
and many other things require a due amount of attention. To allow this, the FST
software provides an easy-to-handle multitasking structure. Within each project,
program 0 enjoys a special status as it constitutes the "mother" of all of the other
programs and is launched on startup. A further 63 programs can be added as needed,
and operate simultaneously.

Variables You can never have enough of them: flags, timers, counters, input/output addresses, to
name but a few. FST takes this to its logical conclusion: 10,000 flag words (that is
160,000 individually addressable bits), 256 timers and 256 counters are sufficient for
even large-scale projects.
Networking Increasingly, however, today's automation projects are not merely large, they are also
decentralised: a large number of small controllers, each with small projects, operate in
concert. Small, clearly organised, fast, easy-to-program projects in small control
systems provide in total a more easily manageable and clearly arranged whole than a
single giant monster. The FST software supports the networking of controllers with the
assistance of traditional fieldbusses such as Profibus DP and FMS, CAN, ASi, Festo
fieldbus etc., but also now Ethernet - the fieldbus of today. With Ethernet it is possible
both to exchange data between the controllers and to program the controllers. From a
single Ethernet connection, direct access can be gained to all of the controllers out
there on the network. Central programming of distributed controllers is the key concept
here. With FST, from the mini controller to the major system, this is already reality
today.
Modules and drivers No programming software can satisfy every requirement. It is only a matter of time
before someone will ask for this or that feature that "my" job needs, but which "they"
have forgotten about. FST has an open interface for modules and drivers. New modules
can be written in C/C++, and new drivers too. In this way, FST is open to expansion,
modification, and adaptation – for small controllers just as much as for large ones.
WEB Server One example of how this open structure is used is the WEB server. A driver allows
access to the I/O level of the controller via an intranet or the Internet. On the basis of
the TCP/IP driver, the controller with the WEB server understands HTML code, the
language of the Internet.
Are you interested in FST? More information is available here:

http://www.beck-ipc.com/fst
http://www.festo.com/fst

These days there is much philosophising about "decentralised architectures",
Networking and "decentralised automation technology" and a great deal besides. Much is written about
remote maintenance the fact that small controllers, small programs and small systems are clearer and more
manageable than large and centralised systems. The theory goes that a large number
of small, autonomous systems are more stable in operation than a large, centralised
system.
How does it look in Well, after all is said and done, people do choose the large controller again, with many
practice? thousands of input/outputs, because it is too much trouble for them to rack their brains
about the small subgroups; and because it is too much like hard work to program every
single station individually; and because it is too complicated to network all stations
with each other and to bring up the network in the right order; and because ...
Anyone who says "decentralised" is the best option must also point out ways in which
"decentralised" can be made practicable. Anyone who says "decentralised" is the way
to go needs a network that actually supports decentralised structures and does not
simply grind to a halt when some component or other fails. Anyone who promotes the
"decentralised" theme must illustrate that programming can be carried out centrally and
that troubleshooting can be performed from a central location.
Networking with Ethernet, programming via Ethernet, operation via Ethernet, remote
maintenance via intranet and Internet, process visualisation.
In this section you will find several examples in which decentralisation is taken
seriously. Enjoy reading about them.
Networking and remote maintenance 35

They are round, and look nicest when they are colourful: toy balls. The technique of
Pad printing pad printing can be used for printing a huge variety of subjects which lend colour to
on a network children's play. But also ball-point pens, cigarette lighters, small packages or
spectacles, in other words relatively small objects with curved or uneven surfaces, can
be printed economically in large numbers in this way. To make sure that the imprint hits
home, mini controllers from Beck are used together with pneumatic feed units from
Festo.
Pad printing brings colour Not multi-coloured but with a single-colour imprint, table-tennis balls fly across the table
into play and golf balls soar through the sky. The toy balls for children are usually larger and
also more brightly coloured. The concept that Printing International has devised with its
latest pad printing machine offers the solution for both variants: a modular system.
Every module, in this case the print head, can print both on its own and in concert with
others. If it is left on its own, just one colour is applied.
Used in combination, multi-colour printing becomes

possible. Advanced network technology and efficient programming tools characterise
the pad printing machines from this Belgian manufacturer. The printing mechanism is
pneumatically driven.
Pad printing is an indirect gravure printing process in which the subject is etched into
the plate; ink transfer takes place with the aid of a flexible medium, known as the pad.
The printing machine consists of a vertical feed unit, a Festo cylinder. This executes
the pad's printing movement. The horizontal feed unit moves the printing plate between
two fixed positions, towards the pad or towards the "ink cup". This process is repeated
after every imprint.
Controlling the pad printing machine is fundamentally a rather simple task. If it is

intended to print several colours and several subjects on a single object, the actions of
the print modules must be coordinated with each other. The possibility of activating
different print heads selectively is offered by the IPC FEC FC34 Front End Controller,
the mini controller from Beck IPC GmbH. In a network version using Ethernet, it takes
care of every aspect of control of the machine.
36 Networking and remote maintenance

Optimum networking - With Ethernet, connections can be plugged in and disconnected without adversely
flexible programming affecting ongoing operation. The modules making up the printing machine can easily
be checked and put into operation individually. The conversion phase for the machine
as a whole is totally flexible, because the modules can be contacted as required and
independently of each other.
If there is a combination of several equally ranked controllers, the question always

arises as to which one has the upper hand in the event of parallel access. Printing
International has found an easy way of solving this conflict: as soon as at least two
modules begin to interoperate, a single "head controller" is added. Here, too, the FEC
shows its strength in action – it directs the entire system with the aid of the FST
programming system, in which the "Step" sequence operation is already integrated.
Whether the ball will then find its way step by step into the goal or across the green into
the hole – at the moment that is still beyond the capabilities of the FEC.
Hardware IPC FEC FC34
Keywords Pad printing, modularity, F34, Ethernet, FST

Every modern town has one now: a pedestrian precinct. And the way they are organised
Securing pedestrian is much the same everywhere: in daytime, during the usual opening times, the
precincts pedestrian precinct is supposed to be precisely what the name suggests: they are
reserved exclusively for the use of pedestrians. In the early morning and the evening,
though, delivery vehicles should be able to bring in goods as easily as possible, and
also be able to pick up goods as necessary.
But how can the observation of these regulations be monitored? Or should we simply
rely on the law-abiding nature of motorised road users?
In Belgium, the method used to maintain the rules is as simple as it is amazing.

Retractable posts have been installed at the entrances to the pedestrian precincts.
During the day, when the area is for pedestrians only, they are raised, but at night they
are lowered into the ground.
Boundary between a
pedestrian precinct and a
road
The job of raising and retracting the posts is taken care of by pneumatic cylinders. The
task of triggering the valves is the responsibility of a small controller – and the neat
thing about this solution is that the controller is connected to the local police
headquarters by modem. The cylinders are automatically raised in the morning, and in
the evening they are lowered again. Once a day the PC (the computer, not the officer!)
at police headquarters polls each controller to establish whether the cylinders are up or
down as they should be, and in order to synchronise the clock in the controllers.
The master computer at A car has been driven into the pedestrian precinct and the driver has forgotten the time.
police headquarters How can he get out? Well, the controller can be called up from the police station and in
exceptional cases the post can also be retracted during the day to allow access to the
road.

Windows NT PC with
Visual Basic Soft ware
Modem
Modem Modem Modem Modem
FEC FC30 FEC FC30 FEC FC30 FEC FC30
2 Cylinder 2 Cylinder 2 Cylinder 2 Cylinder
with valves with valves with valves w ith valves
The controller is an IPC FEC FC30. A particular advantage of this is that it has two
serial interfaces. One is used for the modem, and one – during commissioning and
maintenance – for the programming unit. The police computer is a standard Windows
PC with a Visual Basic application that accesses the controllers.

Pneumatic cylinders, type DNC
Valves, type CPE
Modem
PC Windows NT
Keywords Remote control, telemonitoring, modem, traffic control technology

TURNILS AB is a Swedish company that is one of the world's largest manufacturers of
Recording process sun-shades, awnings, sun-blinds and everything related to such products. With exports
data and arranging for making up around 80% of sales, Turnils is a global player in a market that for average,
essential repairs unaware consumers such as us appears relatively trivial. How many people have spent
much time thinking how sun-shades are made?
The experts at Turnils do a lot of new thinking every day. What makes it more difficult
is that sun-shades and awnings, in much the same way as clothing, are highly
dependent on fashion as far as colours are concerned. And they are purely seasonal
products. If good weather is forecast in a particular area, sales rise. Persistent rain for
weeks on end leaves orders in the doldrums.
In view of the need to be able to respond very quickly, it is particularly important to

have a perfect overview of the current situation in production at all times. The
production planners and machine experts have therefore integrated an IPC PS1 system
Additional serial into the existing manufacturing setup, to function as a data collector. The process data
interfaces are simply is gathered from 19 production robots and 17 injection moulding machines to be
plugged into the evaluated in a Windows PC, giving the production management team an excellent
busboard. overview of the status of production whenever it needs it.

In a further step, the IPC was fitted with a modem. If a problem occurs in production, the
emergency maintenance service can be summoned via the modem. As a result it has
been possible to further expand the number of unmanned shifts and reduce response
times in the event of a fault.

CP31 2 x serial interface
FC/FD10 Floppy disk controller and drive
Modem
Software FST, the universal software with file handling capability and support for serial
interfaces, was once again the software used here.
Keywords Modem, ghost shift, production statistics

In the world of automated production, the reconstruction of individual steps in
Data backup on the production or testing after the event has become enormously important. During the 70s
network the concept of CIM - Computer Integrated Manufacturing - was illustrated by the
example that a manager can interrogate the limit switches in the production plant from
his PC. The problem was that the manager wasn't in the least interested in these limit
switches, and networking technology also needed another few years of development
work until this vision could be made reality. Today it is not a matter of being able to
interrogate data just for the fun of having data. What is important is being able to ensure
unbroken tracking of production data and testing data.
When, for example, the bolts on the engine block of a new engine are tightened, it is
not only important to know that a bolt has been inserted at all but also that the bolt has
been tightened using the defined tightening torque and that bolting has therefore been
successfully completed using the defined force. Cooper Power Tools (CPT) has
developed its own bolting controller for dealing with bolting tasks of this nature. The
controller is capable of carrying out conclusive checking of the bolting during the
bolting process. The data arising for each individual bolt must be saved automatically,
and must remain available for at least 10 years.
Bol ting
server
Windows
NT
Interface PC
Ethernet
CPT CPT CPT CPT

bol ting b olting bol ting b olt ing
cont r oller controller cont r oller con troller
Bol t t ightener Bol t t ightener Bol t tigh tener Bolt t ightener
CPT has therefore networked its own bolting controller with an IPC PS1 system, and in
turn it has integrated the PS1 system into the customer's in-house Windows NT
network. The data from the bolting controllers is stored on the IPC PS1's local hard
disk; it is then transferred on a cyclical basis to the NT network, where again it is
backed up on hard disk. Every day the production data is written to CD, and the CD is
placed in storage. In addition, the NT network is regularly backed up as part of the
general data backup procedure for the IT systems.

In general terms, in this application the IPC PS1 Professional acts as a gateway
between the bolting controller and the customer's local network. As well as the simple
gateway function, though, it fulfils two other tasks.
Firstly, the local hard disk acts as a buffer store. The storage facility is actually
divided into two: in step with production, the data is initially stored in a battery-backed
RAM, then in a cycle of a few seconds it is written to the hard disk before finally in a
cycle of a few minutes being transferred to the local network.
Secondly, with the aid of its input/output modules the IPC PS1 can also carry out
control tasks "on the side". This feature has had the result that, in the course of time,
control tasks have also been transferred to the gateway, for example for belt control,
component feeding etc.
In this way, a simple gateway has turned into a controlling and storing gateway.
Hardware The basic equipment set generally looks like this:

HC20-50 32-bit CPU with 586 processor, Compact Flash slot
HD51 2 GB hard disk
Software Programming is carried out in C/C++, the simplest method in a gateway optimised for
the Windows network.
Keywords Gateway, Windows NT, hard disk, buffer storage

The Russian company Svetogorsk operates one of that country's largest factories for
Modernisation of a paper products of all kinds. A high-bay warehouse was built there in 1987, extending
high-bay warehouse over 6 floors and with up to 20 rows, each with up to 40 pallets. In 1999 work was
started on modernising the high-bay warehouse. On 3 of the 6 floors, initially, the
handling equipment was replaced with vehicles driven by frequency-controlled electric
motors. In addition, the data management system and control of the store system were
renewed.
The head controller for the system as a whole is an IPC
PS1 Professional system with an HC20. HC01 CPUs are used on the modernised
floors. The HC01 CPUs control the vehicles, which have to be positioned with an
accuracy of 6mm within the rows, each of which are 80m long.
The HC20 controller is equipped with 8 serial interfaces, some of which are in the form
of RS485 bus systems. These are used for communication with the modernised floors
and with the floors that have been left in their old condition for the time being.
Ethernet is used for communication with the operator terminal. This is where all the
data management work for the high-bay warehouse is carried out, as well as operation
of the system, on a standard PC.
There are a number of subcontrollers each responsible for a single vehicle. HC01
CPUs are used for this. The positioning system uses the fast counter input provided by
the HC01, which picks up signals from a rotary pulse generator.
In the course of the year it is intended to convert the remaining floors as well.
Altogether, in the final configuration, 56 PS1 Professional systems are planned
throughout the building.
Hardware Head controller:

3 x CP3X Serial interface
Individual controller for a number of rows in the high-bay warehouse:

HC01 AM186 CPU with 8 digital I/Os
Software The software was developed by AKMA Ltd (e-mail: aml@akma.spb.su), a company
based in St. Petersburg. AKMA has devised its own real-time kernel for DOS systems,
and this is used in this application. The languages it uses are C/C++ and Assembler.
An integral part of the real-time system is a monitor for troubleshooting; this allows
direct access to the variables in the CPU for development work and fault finding.
Keywords High-bay warehouse, Real Time, Ethernet, fieldbus

Isabellenhütte is a company in Dillenburg, central Germany, with a tradition stretching
Calling the emergency back 500 years. This company is living proof that long-standing tradition need not lead
repair service to fossilisation but can instead very much bring about advancement and a wealth of
ideas. Today the Isabellenhütte is considered one of the world's leading manufacturers
in the field of electrical resistor materials – whether in the form of resistors for the
production of printed circuit boards or in the form of thermal wires and resistance wires.
Twisting thermal wires The manufacture of thermal wires and resistance wires entails first drawing ever finer
wires, and then also twisting several fine and extra fine wires to produce the final wire.
This process of twisting a number of extremely fine wires together is performed
automatically on machines specially made for this purpose. The reels for the initial
products and end products are designed so as to enable the units to operate for up to 36
hours without interruption. The operating personnel ensures that the machines run
around the clock, 7 days a week – human intervention is only needed in order to
change the reels.
What happens, though, if shortly after the new reels are put in place a fault occurs, for
example a thread breaks or a reel becomes jammed? It used to be the case that the
plant had to wait – until help arrived more than a day later.
Automatic fault detection Mr. Eichmann is the engineer responsible for the machinery at Isabellenhütte,
especially for production of the special-purpose machines that the company builds and
programs itself. In order to reduce the length of stoppage times in the event of faults
during the "ghost shifts", Mr. Eichmann now uses a small control cabinet with an IPC
PS1. The IPC PS1 receives digital fault signals from the manufacturing equipment. The
fault groups are indicated with the output module. What is more important, though, is
that a message is sent to the responsible emergency repair service with the aid of a
modem connected to the RS232 interface.
The PS1 system calls for The fault is reported to the emergency repair team on a paging service (Scall)
help wristwatch receiver. The downtime for the machines is now reduced to the length of
time that the emergency team needs to get to the factory and repair the machinery.
Hardware BP11 3 x busboard with power supply

MC10 PCMCIA module
Modem
Software For Mr. Eichmann, Basic is the fastest and easiest method of achieving success.
Keywords Fault monitoring, ghost shift, modem, Scall receiver, Basic

As an exhibit to be used for presentation purposes at trade fairs, a device has been
Calling the machine developed that illustrates the possibilities offered by mobile telephony in conjunction
with automation technology in a particularly attractive way. A traditional type of
automatic chewing gum dispenser, of which there are hundreds of thousands in use
wherever it is hoped to do a trade in small sweets or gifts for a few pence, was fitted
with an electric drive. Control of the drive is taken care of by an FEC FC38. This is a
mini controller with an integrated GSM modem.
The GSM modem and the controller communicate via the second serial interface on
the FC38, the EXT interface. As a consequence the FC38 can basically be
programmed in any programming language, provided that it supports the EXT interface.
As well as this, a special software package was developed, TCM-SMS, which
evaluates SMS messages. This package firstly enables the controller to send an SMS
message. It is also possible, however, to issue commands to the controller with the aid
of SMS messages, in other words for example to switch outputs, read out inputs etc.
The software was adapted for the chewing-gum dispenser in such a way that it is
enough just to make a phone call to the machine. The call and the calling number are
logged. In this process, though, the call is not answered (that would incur call charges
for the calling mobile phone every time). The fact is merely recorded that an attempt
has been made to make a call. When a call is logged, the motor is activated to enable
the machine to give out a small gift.
Keywords GSM, remote control, remote maintenance, mobile phone

Many experts are still not really happy to let the words "Internet" and "automation" pass
Control and operation their lips in the same sentence. The "toy" and knowledge database that is the Internet
via the Internet seems just too far removed from the clear and predictable (or so they should be)
applications in automation technology. It is only gradually that many users are
becoming aware that the technologies of the Internet offer enormous opportunities for
automation: remote maintenance, remote control, visualisation and a good deal more.
As an illustration of what is possible with very simple means, a number of examples

are available on the Internet.
_ If you go to http://fc34demo.beck-ipc.com you will find an FC34, i.e. a real mini
controller, showing that already today it can be used as a WEB server at the same
time as being used as a controller.
_ At http://fstdemo.beck-ipc.com you can see online on the Internet how the language
of the Internet, HTML, can be used to display and change process variables.
_ And at http://webdemo.beck-ipc.com the IPC@CHIP shows that it can make a small
meteorological station available on the Internet.
Hardware
FC34 Demo IPC FEC FC34 Mini controller
DGO cylinder Linear drive
CPV valve terminals
FST Demo BP11 3-slot busboard with power supply

AS11 Input/output module, each 8-bit, with pushbuttons and LED
WEB Demo IPC@CHIP The entire IPC on one chip

DK40 Evaluation board
Keywords Internet, WEB server, FST, remote control, remote maintenance, visualisation

Many programming methods used in automation technology are good, well known,
Programming in line simple or complicated, or they may have unique properties which enable them to tackle
with IEC 6 1131-3 with one task or another particularly well. Only one programming method is internationally
MULTIPROG standardised, internationally accepted, and internationally established – programming
in accordance with DIN IEC 6 1131-3.
The Edit Wizard and the

online help ensure
handling of IEC 6 1131 to
be fast and easy.
This standard, actually adopted many years ago now, is the only internationally
recognised method of PLC programming. Not only that, it is the only PLC programming
method that is promoted, tested and distributed by an independent institution, the
PLCOpen.
At the same time, IEC 6 1131-3 allows the user a great deal of freedom. Five
programming languages are standardised:
The 5 languages of the The text-based languages Instruction List and Structured Text, the graphical languages
standard Function Block Diagram and Ladder Diagram and Sequential Function Chart for
organising sequential systems.
The IPC systems, ranging from the FEC mini controller to the large IPC PS1
Professional system, are all programmable with MULTIPROG, one of the leading IEC
1131-3-compatible software packages.
Wizards and dialog boxes MWT has not only translated the standard into practice, it has also introduced tools
which simplify handling of the standard and make it user-friendly: wizards for making
use of functions and function blocks as well as dialog boxes for the declaration of
variables – familiar to all PLC programmers as the allocation list.

For programming and
debugging via TCP/IP
only the IP address is
necessary.
Networks From the very beginning, IEC 6 1131-3 has taken account of the fact that modern
automation technology cannot work without networks. For this reason, MWT can
manage entire networks in a single project, with dozens of CPUs. When IPC central
processing units are used with Ethernet, every controller can be accessed via Ethernet
– from a central location with one Ethernet connection and one programming unit.
Programming according to IEC 6 1131-3 has long ceased to be an exotic exception.

The range extends from mini controllers to large networked systems.

The project tree of
MULTIPROG
Data types IEC 6 1131 detaches itself from the usual data types in the PLC world. In addition to
bits, bytes and words, it supports a large number of other data types. Depending on the
possibilities offered by the particular hardware, INT, DINT, DWORD, UINT, REAL and
STRING can be used, among others. This considerably extends the potential uses of
PLC programming. MULTIPROG exploits this potential, and also offers a large number
of options for converting data types.
Local/global flags At last it is now also possible to use local and global flags in PLC programming. The
name “Start” can be used perfectly well in several programs, and in each program it
refers to a different flag – and is therefore local. This makes handling flags much
easier.
Timers and counters In traditional PLCs, the number of timers or counters that a controller provides is
specified. MULTIPROG may include just one block for an on-delay function, for
example. The block can be called as often as the application requires (and the memory
in the CPU allows). Limits are set by the application, no longer by the programming
system.
Ladder Diagram / Today’s Ladder Diagram uses NO contacts, NC contacts, coils and so on in just the
Function Block Diagram same way as Ladder Diagram has since the start of PLC development. Every block,
whether for example for a counter, a calculation, a flip-flop or any other subprogram, can
be integrated into Ladder Diagram. These blocks look precisely the same as in
Function Block Diagram. This means that the boundaries between Function Block
Diagram and Ladder Diagram are disappearing; the two can be used immediately
alongside each other in every program or block.

Sitting in your living room poring over the statistics on the discharge of pollutants from
Measurement old contaminated industrial sites and the consequences for the quality of our drinking
technology, data water is one thing. Gathering the data for those statistics is quite another.
processing and quality
assurance Writing a specification and an accompanying form for the acquisition of data on the
tensile forces of wheel bolts on a car is one thing. Actually collecting the data and
storing it in a meaningful way is quite another.
Discussing the sense or lack of it behind catalytic converters, diesel particle filters and
speed limits on roads is one thing. Obtaining the necessary data for a scientific
assessment is quite another.
The PC architecture underlying the entire system of IPC FEC and IPC PS1 controllers
in conjunction with optimisation for minimising power consumption provides the ideal
prerequisite for operation as a data collector.
In this section you will find various examples which concentrate on the acquisition,
storage and transmission of measurement data. Enjoy your read.
Measurement technology, data processing and quality assurance 51

To comply with environmental directives, operators of abandoned potassium mine spoil
Collecting and heaps are obliged to provide continuous proof of the salt loading in the neighbouring
processing river and if necessary, if certain levels are exceeded, to initiate countermeasures.
environmental data In order to monitor this type of problem, the conductivity
of the water is constantly recorded at six decentralised measuring points (upstream and
downstream of a potash heap in each case), and the chloride concentration is
calculated from that.
The IPS1 system in this case acts as a data logger. The data source, a conductivity
meter, makes its measured values available at the COM2 (CP30) port face every
second. The implemented software then has the task of breaking down the serial data
stream into the required data components and of converting the conductivity into the
chloride concentration. Over an interval of two hours the mean value is calculated and
the minimum and maximum values are identified. These 3 values together with the
temperature are assigned a time stamp and stored. For reasons of furnishing proof, the
momentary measured values are logged every minute for a period of 30 days in a ring
memory on the memory card. In the event of an incident, the data can be read out from
the memory card.
Five of these measuring stations are housed in a small control cabinet close to the
river bank. Every conceivable type of weather experienced in central Europe is thrown
at the PS1. In several months of continuous operation, the system successfully
passed its test in action.
On the basis of this measurement data it was possible to prove that neither fluctuations
in temperature (moisture condensation) nor decidedly chilly temperatures of below -5°C
(even over a number of days) had resulted in any failures.
The decision to choose the MC10 module with a 1MB SRAM card as the storage
medium proved to be the correct one in these harsh ambient conditions.
The COM1 (HC12) operates the trunked mobile radio unit. The switch output pin7 of the
CGA port is used to check the radio unit into the trunked radio network at least once a
day.
The COM3 takes over the role of a service interface. System parameters can be
visualised and modified on location with the aid of a notebook.
Three of these measurement systems are located far away from civilisation. They are
supplied with power from photovoltaic installations. In this instance it was important to
save every possible milliampere. This is why the HC20-40 is used, with its two serial
interfaces and the flash memory. Any components that are not required, such as VGA,
are deactivated in the setup. This offers advantages with regard to power saving.
Especially as the local fauna is unlikely to be interested in reading the measurements
on a monitor.
In order to make the measurement data accessible to the plant operator, at intervals of
two hours it is automatically transmitted via public trunked mobile radio to a mainframe
(AS/400), where it is archived. This task is dealt with by another PS1 system. It acts as
a radio server, and communicates with the AS/400 via the in-house LAN topology.
52 Measurement technology, data processing and quality assurance

As far as the radio interface is concerned, a highly efficient and cost-effective means of
data transmission was organised by using the MAP27 API with the SDM/EDM
functions.
The entire system operates autonomously. Manual access to the functionality is only
necessary for the purpose of administrative procedures. In this case the decentralised
measuring stations can be operated by remote control in remote mode. The
infrastructure of the trunked mobile radio network means that the data can be accessed
anywhere in Germany. A significant contribution to the overall stability of this highly
independently operating measuring system is the watchdog function that is
implemented.
Every aspect of the functionality of the measuring system including the radio interface
to the MAP27 API was written in C/C++.
Hardware Device Radio Measuring Measuring

server station station
Number 1 3 3
BOSCH KF-CHIP radio unit X X X
BP11 3-slot busboard X
BP50 5-slot busboard X X
CP10 Ethernet interface X
CP30 RS232 interface X
HC12 PC/CHIP CPU X X

HC20-40 32-bit CPU,
486 processor, CF, flash X
LF340 WTW
conductivity meter X X
MC10 PCMCIA module X X
SM14 TTL/RS232 adapter X
ZL16 Zero power RAM disk X X
ZL31 1 MB SRAM X X
Software ROM-DOS, firmware: FunkServ, LF_Val, MAP27.LIB
Keywords Environmental monitoring, telemonitoring, remote maintenance, conductivity

measurement, data logger, preservation of evidence, ambient conditions, power supply,
public trunked mobile radio, radio server, autonomous measurement systems, C/C++,
watchdog

Research work carried out at the Bauhaus University in Weimar includes the
Observation of supervision of historically valuable buildings and structures such as churches and
historical buildings bridges. The aim is to prevent deterioration. The relevant physical quantities relating to
and structures the structure are monitored and diagnosed using mathematical models, so that if
necessary a restoration plan can be drawn up in good time.
The consultant engineers, ISL Ing-Büro für Systemlösungen in Erfurt, use the IPC PS1
as a long-term data storage facility.
Critical measuring points include the beams of a church tower, for example, when
subject to changing wind load and the varied influences of weather.
Another application is the long-term observation of the load behaviour and response to
weathering of a historically valuable bridge. What needs to be done here is to
document the "healing success" with data from about 1 year before, during and after the
renovation of such a bridge.
The hardware basis is provided by the Spider 8 measuring instrument from HBM and
the PS1 system. The entire functionality of the Spider 8 is stored as an image in the
PS1. The Spider 8 and PS1 communicate via the COM interface using a corresponding
software protocol.
Various modes are implemented on the user side:
a) Direct coupling between PS1 and notebook (usually at the time of initial
installation or when adjusting the measuring bridges on location)
b) Coupling of PS1 via modem
c) Coupling of PS1 via GSM radio unit (inaccessible terrain with no infrastructure, no
230V supply, no telephone connection)
d) Coupling between PS1 and private mobile radio equipment
e) Autonomous data transfer to the server (script-controlled)
In modes a) to d) the operator obtains an image of the entire system displayed on his
PC/notebook. In remote mode he can parameterise the installation, configure it,
balance (calibrate) sensors, define filter rates and sampling rates, etc. The
measurement data is transmitted using a transfer protocol (X-modem). A formula editor
is implemented which enables the integer measured value to be presented as a
physically relevant measured quantity.
In the subsequent expansion stages dynamic and event-controlled measurements will

also be used with the assistance of HC20 or HC50 modules. As a result it will be
possible, for example, to assess bridges under rapidly changing loads (trucks, trains).
A major contribution to the overall stability of this autonomously operating

measurement system is provided by the watchdog function that is implemented.

The PS1 proved its mettle both in use in severe environmental conditions (during the
building phase) and in relation to its all-weather resistance (at times in external
temperatures of -5°C according to the measurement data).
The entire functionality of the measurement system including the transfer interface was
written in C/C++.
Hardware Long-term measurement

HC12 PC/CHIP CPU
ZL16 Zero power RAM
MC10 PCMCIA module
ZL31 1 MB SRAM
CP30 RS232 interface
ZP11 Modem
Spider 8 HBM
Dynamic long-term measurement

HC20 32-bit CPU, CF, flash
MC10 PCMCIA module
ZL32 2 MB SRAM
2*CP30 RS232 interface
Modem
4*Spider 8 HBM
Software ROM-DOS, firmware: S8PS1D, S8ContrlWin, Trans_Srv
Keywords Physical properties of structure, telemonitoring, remote maintenance, long-term data

storage, environmental conditions, modem, radio, autonomous measurement systems,
C/C++, watchdog

When tyres are fitted they initially have to be inflated to a relatively high pressure so as
Compressed-air filling to achieve a perfect fit with the wheel rim. The pressure is then reduced to the
station for tyres appropriate mounting pressure.
Depending on the type of tyre, the initial pressure may be 5 bar, for example, and the
final pressure 1 bar. Inflation and to some extent pressure reduction is carried out
automatically.
The difficulty with pumping air into the tyre is that air is supplied through a valve. The
valve acts as a throttle. This has the effect that it is never possible to measure the
pressure and pump in air at the same time. Consequently, the tyre is always inflated for
only a short time, then the pressure is measured, inflated, measured...
At the Swedish manufacturer, the intelligent solution produced with the IPC PS1 has
reduced the time needed for inflation by 50%. To achieve this, the IPC recalculates the
assumed inflation time at every inflation stage on the basis of a previous inflation
process. It is only when the inflation level is calculated to have reached 90% that the
inflation process is interrupted, a measurement is taken and a new calculation is
performed, etc.
This is therefore a self-optimising closed-loop process control function.
Hardware PB31 8-slot busboard

HC16 PC/chip CPU, EPROM, RAM, flash
I010 8 x analog input module
BG10 4-line LCD display with 4 function keys
Software Programming is carried out in Pascal, because the emphasis is less on controlling the
input/outputs than on the calculation algorithm.
Keywords Self-optimising closed-loop process control, pressure measurement, Pascal

Soil tests which investigate the density or compaction of the soil are very important in
Automated soil agriculture. Also the question of the extent to which the tyres of a tractor compact the
examination soil, for example, is important for assessing the possible ways in which the vehicle can
be used.
In Belgium a vehicle has been developed that carries out measurements of soil
compaction automatically and saves the measurement results. To do this, it measures
the force that is needed to enable a rod to penetrate the ground down to a specified
depth.
The IPC PS1 controls two of the axes, X and Y. In the X-axis a stepping motor is used
in order to obtain a series of measurement results, which are then saved. In the Y
direction the measuring rod is extended and the force is recorded. The measurement
data is stored in Excel format in the flash drive belonging to the CPU, and at the end of
a series of measurements it is read out via RS232. In the office the data is then edited
and evaluated using standard software.

OM20 Digital input/output module, each 8-bit
AM11 Stepping motor module
Software Pascal
Keywords Soil examination, Excel, flash drive, force measurement

Tipptronic is a semi-automatic gear-shift system for cars. The driver selects a gear with
Testing Tipptronic the selection lever, and the gear is set electronically. There is no clutch for the driver to
system modules operate. The electronics also monitors whether the selected gear makes sense.
Changing into reverse gear when travelling at 70 miles per hour on the motorway is
therefore made impossible electronically. It goes without saying that the selection lever
must always issue an unambiguous instruction to the electronics. And this instruction
must precisely correspond to what the driver wants to do.
Hüco electronic GmbH manufactures these Tipptronic components and tests the
system with the IPC PS1 Professional. The core of the Tipptronic is a curved printed
circuit board with Hall sensors. The purpose of the test stand is to check whether the
Hall sensors correctly signal the position of the selection lever.
The various positions of the selection lever are simulated with the aid of pneumatic
cylinders, triggered by Festo valve terminals, with a magnet mounted on them. The
gear selection status is output on LEDs. The state of the LEDs is picked up by
photoresistors and is reported back to the testing system.
What was important during the development of the test stand was that the system had
to be very easy to adapt to new requirements, new shapes, and new types. From the
beginning, the test cabinet was designed to allow space for expansion.
A number of files are created for each component type, for example the job file, the limit
value file and the CAQ file, where the measured data is stored. Altogether each
measurement procedure currently amasses 37 measured values.
The measurement system is operated using a standard keyboard and monitor – as far
as the measurement itself is concerned. The photo shows the control cabinet with the
IPC PS1 together with the 14" monitor and the keyboard, as well as to the left of these
the label printer. In addition the AS11 module with its 8 pushbuttons and LEDs is used
in order to switch back and forth between various limit value files.

Hardware BP40 14-slot busboard built into a 19" rack
HC20-80 32-bit CPU with 486 processor with mathematical coprocessor
HD50 1 Gbyte hard disk
AS11 Combined 8-bit digital input/output module
CP30 RS232 interface for the label printer
OM70 6 x relay output module
OM22 Digital input and output module, each 16-bit
Software The approach to programming was split into two: the control section including the test
sequence was written in Step5, while the user interface, measured value acquisition,
evaluation and data backup were written in C/C++. The two programming systems are
connected via the real-time multitasking system on the basis of RT Kernel.
Keywords Tipptronic, S5, C/C++, measured value acquisition, Hall sensor

Testing, testing, testing ...
Testing Checkbox
modules It is a fact that we are all familiar with: the more complex the module, the more elaborate
the testing becomes. The Checkbox is a system for feeding correctly oriented small
parts that checks the parts at the same time (see the description of the Checkbox in the
section on control technology). The electronics for this are without doubt among the
most demanding examples known. This is because the CPU is optimised for
evaluation of the camera images and simultaneously controlling the input/outputs in the
system.
Apart from the in-process tests which every electronic module undergoes in the course
of production, a final test is absolutely essential. In the case of the Checkbox hardware
this has to be very flexible so that the test can be adapted to various versions of the
CPU.
Once again, the IPC PS1 was chosen as the centrepiece of the testing station,
although without doubt one reason for this was that the Checkbox team were already
thoroughly familiar with the IPC PS1.
An HC16 CPU, which in this case is able to concentrate entirely on testing, is quite
sufficient here. A BG20 takes care of the graphical representation of the whole testing
process, and input/output modules provide signals for the electronics under test, to
which it has to respond.

Needless to say, the test procedure also includes storage of the test data and
subsequent evaluation in a database.

IO60 4 x analog output module
BG20 LCD display
Software Programming is carried out in C/C++, because that is everyday routine for the Checkbox
team.
Keywords Electronics testing, Checkbox

Inert-gas-shielded welding is one of the most commonly used welding techniques when
Monitoring welding producing circumferential welds for bicycle frames or similar products.
data As in so many cases, the testing of welds such as these is now a vital part of the
manufacturing process. Where automatic test procedures are used, it makes sense to
record the welding parameters while the actual welding operation is still in progress.
These include the welding current, the flow of shielding gas and the welding voltage.
Weber Robotertechnik GmbH has developed a system which detects the key
parameters determining the quality of the welded seam independently of the welding
control system. The SDC – the welding data controller – is integrated into the welding
system and is totally transparent for the welding controller.
The SDA – the welding data display – processes the data. In the simplest case, this
includes calculation, with the result being a decision to accept or reject the weld,
through to detailed graphical output on a printer or onto a network on a higher-level
control desk.
Inside the SDA there is an IPC PS1 Professional beavering away, which is ideally
suited to the task because it provides all of the necessary input/output modules to the
SDC, the system remains small enough and programming of the PC-based system is
no problem for the developers at Weber.

CP70 Printer interface
CP31 2 x serial interface
Software Programming is carried out in C/C++.
Keywords Welding, inert-gas-shielded welding

By measuring the carbon monoxide (CO) and oxygen (O2) at the flue gas outlet header
Optimisation of a gas- of a gas-fired power station, conclusions can be drawn as to the level of gas
fired power station consumption and waste gas emissions by the power station.
In order to reduce gas consumption and therefore also emissions in an existing gas-
fired power station in Spain, a measuring system with an IPC PS1 is installed at the
flue gas outlet header; this exchanges data with another IPC in the central control room
via an RS485 interface. In the control room the data is visualised and incorporated in
the process control system.
This feedback arrangement therefore enables process optimisation to be implemented
within power station operation.
The rugged and compact design of the PS1 system allows it to be used directly at the
measurement location (the flue gas outlet header) under the difficult ambient conditions
prevailing there for direct recording of the analog measurement signals from the gas
sensors. This results in a cost-effective measurement system.
Hardware IPC at the flue gas outlet header

PS1-PB31 8-slot busboard
PS1-PS10 Power supply unit
IO11 8-channel analog input module
IPC in the process control room

PS1-PB31 8-slot busboard
PS1-PS10 Power supply unit
PS1-HC12 PC/CHIP CPU, EPROM, RAM
PS1-VM12 VGA module
Additional components:
Measurement system for CO and O2 (gas sensors)
Link between the two IPCs over a distance of about 200m via RS485
Software Programming was carried out in C, because in that way adaptation to the existing
system was easy and flexible.
Keywords Process optimisation, measurement of gas emissions, process control system,

process visualisation, RS485, C/C++

Quality assurance in
cylinder manufacture
A test station in which pneumatic cylinders are tested in various steps is controlled by
an IPC PS1. The crucial test step is the leak test performed with the cylinder at its
various operational stages (extended and retracted). The test principle used is
measurement of the pressure drop. The cylinder is pressurised and hermetically
sealed. The pressure drop within a defined period of time and depending on the size of
the cylinder must not exceed a specified value.
Various pressure levels are set with the aid of a proportional valve, depending on the
type of cylinder involved. This calls for the use of a computer-controlled D/A converter.
In order to be able to evaluate the test results in the central computer, the test system
is connected to the company's local area network and thereby to the QA computer.
After conclusion of the test phase, the program is stored in an EPROM. This means
that no mass storage is required, the system is immediately ready for operation on
startup and operational reliability is enhanced.
Hardware PB31 8-slot busboard

DIS2 LCD display
Software The entire program is written in Turbo Pascal. The LAN is a Novell network, so the
measuring station is a Novell client.
Keywords Quality assurance, pressure regulation by proportional valve, Ethernet, Novell, Pascal

A research project conducted in collaboration with UNICEF is intended to provide
Acquisition of information on, among other things, the connection between energy transfer in the
measured data and atmosphere and the phenomenon known as the jetstream. The required data is
controlling an aerial in collected in a balloon. In addition to the measuring instruments, the balloon also
a measuring balloon contains a telecommunications unit that operates via a satellite link. This means that
the aerial alignment has to be continuously corrected in order to track the appropriate
satellite.
Data collection and aerial control are taken care of by an IPC.
The IPC receives the digitised measured values from a device for measuring the field
strength of radio waves, assigns a time stamp to the values and stores them. Because
umpteen thousands of measurements are taken in the course of a flight, the data is
stored on a floppy disk.
The alignment of the aerial is adjusted using an electric linear drive, which is controlled
from a digital output on the IPC. All of the indicating and operating options offered by
the IPC system are reduced to a minimum, to keep energy consumption down. The
operator actions required for starting the system are therefore performed via a key and
LED module.
IPC PS1 is predestined for this application because of its PC compatibility, its rugged
and compact design and the possibility of running it in energy-saving 12 V mode.
Hardware PS1-BP50 5-slot busboard with power supply

PS1-HC12 PC/CHIP CPU, EPROM, RAM
PS1-AS11 Input/output module with 8 pushbuttons and 8 LEDs
PS1-OM20 Digital input and output module, each 8-bit
PS1-FC10 Controller for a floppy disk drive
PS1-FD10 Floppy disk drive
Software Programming was carried out with Quick Basic; this meant that the values taken from
measuring the field strength could be transferred using a simple digital interface.
Keywords Measured data acquisition, measurement of field strength of radio waves, satellite
telecommunications, energy consumption, Quick Basic

Rubber (caoutchouc, India rubber) and similar materials are used in an endless number
Examination of rubber of different forms and an endless number of different applications: as vibration dampers
compounds or seals, as toys or braking elements, bonded or screwed, and so on and so forth.
A huge range of different requirements have to be met, depending on the particular use.
And depending on these requirements, different mixtures of the parent materials have to
be used. With a great deal of experience and sophisticated calculation algorithms it is
possible to draw conclusions as to the composition of the material and the mixing ratio
of the starting materials on the basis of stress tests.
Scarabaeus is a company that has developed the know-how to perform and evaluate
slow-running automated load tests. The particular skill in this connection is to match
the temperature and the course of the stress tests to each other correctly, and to record
the material behaviour accurately in a single series of measurements. The series of
measurements with its ups and downs of material deformation and material reaction
can be evaluated mathematically. The evaluation provides an indication of whether the
material is suitable for the stated purpose or in what way the mixing ratios need to be
changed in order to better adapt the material to the requirements.
The hardware for the control system consists of two separate IPC PS1 systems. One is
responsible for controlling the stress test, and one deals with recording the
measurement data. The measurement data is sent cyclically to a higher-level
computer, which takes care of graphical representation and further evaluation of the
data.
Several versions of the entire system were programmed in C/C++, because this offers
the best flexibility in dealing with data and communications. The disadvantage of this
form of programming, though, is that troubleshooting in the program is relatively

difficult. This is because the high-level language system always assumes that the
program editor and the target system are available at the same time on one computer.
In this case, however, the target system is the IPC PS1, while the programming
workstation can be any Windows PC. For this reason the programming was switched to
MULTIPROG. This programming system provides the possibility of dealing with the
widest variety of data types, including real numbers, and performing calculations with
them. The Structured Text programming language is also similar to the familiar C or
Pascal environment, which meant that familiarisation went very quickly.
Hardware A typical system has roughly the following components.

CP30 Serial interface
Software MULTIPROG
Keywords Material test, rubber, MULTIPROG

Even if it is the case that hydraulic, pneumatic, vacuum or other valves are nowadays
Testing CAN valves supplied more and more often with fieldbus connections, there is barely a single
product line that is produced exclusively with a fieldbus connection.
The CAN bus has a particularly important part to play in the field of automobiles and
trucks. This is not solely due to the fact that CAN was originally developed for car
manufacture. It is also a fact that the CAN chip, in other words the hardware for CAN, is
particularly inexpensive thanks to mass production, and this makes CAN interesting for
large-scale applications such as cars, trucks etc.
If a manufacturer intends to supply valves for this field of work, he will usually offer an
existing valve series with the addition of a variant with a CAN interface.
In manufacture, this additional variant imposes new requirements on the organisation of

production. Above all it is necessary that the newly introduced variant should also be
tested: 100% test, statistical quality control, backing up of the test data, constant,
reproducible test criteria – all necessary adaptations to the new variant of the valve
with a CAN interface.
The Atega box on the test ATEGA, a company based in Völklingen, near the Franco-German border, has
line developed a small test box to cope with this problem; it is simply integrated into the
existing production chain. It is only when confronted by valve types with a CAN
interface that the test does not apply directly to the valve solenoid but instead is run via
the ATEGA test box. The box uses the CAN protocol to switch, test and check the
valves. The essential advantage of this is that the manufacturer is able to retain his
established production line and simply has to slip the CAN valves in between. Thanks
to the PS1 system, the test box is small and manageable despite being equipped with
the BG10 for operator guidance.
ATEGA has also made it possible to integrate special customer-specific

communication protocols in addition to the standard fieldbus protocols by means of a
universal PS1 module that they have manufactured themselves. An ATEGA level
converter takes care of the task of adaptation and tests the product; in all of this,
production remains as flexible as before.

The Atega box in
development

HC27 CPU 486 DX25
CP30 RS232 interface
OM21 8-bit digital input and output module
OM70 6-bit digital relay output module, 8A
CP81 CAN interface
DK10 Blank module with the ATEGA adaptation
BG10 Operating terminal
Software All of the programming is done in C++. For this, ATEGA uses a developer CPU
equipped with a hard disk for code development, debugging and compiling. The
finished EXE file can then run in a CPU with a smaller hard disk.
Keywords Fieldbus, CAN, flexible testing, quality control, C++

Soot content – why do we need to know about that? Now that emissions of sulphur and
Measuring soot nitrogen oxides are not as significant as they once were, because flue gas
content in the air desulphurisation in power stations and catalytic converters in cars are taking effect,
measuring soot content is becoming more and more important. What this means,
though, is not measuring the soot that you can knock off the washing hanging in the
garden, as was still common in the vicinity of coal-fired power stations or steelworks
some 30 years ago. This is about measuring extremely fine soot particles which are
respirable and which have adsorbed pollutants on their surface. These particles are
produced in internal combustion engines. Soot of this size can be measured with an
Aethalometer, anywhere from the Antarctic to the centre of Frankfurt. And the IPC PS1
is always there as well.
International cooperation Software that was developed at an American university, the computer technology of IPC
PS1 Professional, production technology honed in a Slovenian high-tech workshop,
marketing capacity provided by an expert in Bad Homburg – all of this combined
produced the Aethalometer, an automatic measuring instrument used in environmental
protection.
How does that work? The air is directed through an optically homogeneous quartz paper. A sophisticated
system of sensors detects changes in the colour of the paper. The computer calculates
the soot content in the air from the rate of change of the blackness of the paper and the
flow of air through the paper. The data is time-stamped and saved. Depending on the
particular application, the data is temporarily stored in the system, fed directly into a
network or retrieved by modem at specified times.
In environmental protection, it is always a requirement that measurements should be

precise and reliable. The Aethalometer helps to achieve this.

OM10 16 x digital input module
DIS 2 LCD display
Software The programming was carried out in C/C++, as would be expected from an American
university.
Keywords Soot measurement, Aethalometer, environmental protection, telemonitoring, modem,

C/C++

Two measuring receivers, each of which is controlled by an IPC via a separate RS
Monitoring a radio 232C interface, have the task of monitoring a radio station's HF band. This converter
station's high- station is located on Mount Kilimanjaro at about 6000 m above sea level. Because
frequency band frequent power failures have to be expected in such a situation, a 12 V car battery is
used as a simple uninterruptible power supply unit.
The IPC PS1, which records, stores and preprocesses the measured values from the
receivers, is integrated into an Ethernet network via which it is operated by remote
control.
The IPC PS1 is particularly well suited to this task thanks to its ruggedness, its PC
compatibility and its ability to work with a 12 V supply while consuming little power.
Hardware PS1-BP11 3-slot busboard with power supply

PS1-HC17 PC/CHIP CPU, EPROM, RAM, flash
PS1-CP30 Serial interface (2 x)
PS1-CP10 Ethernet interface
Additional components:
2 measuring receivers
Battery and charger
Software Pascal
Keywords Measured data acquisition, remote control, Ethernet, 12 V operation

Modern-day automation technology has long since advanced beyond the boundaries of
Programming in C/C++ Boolean algebra. Whether it is a matter of processing analog measured values, storing
test data, the visualisation of production returns or the continuous acquisition of
operational data – the simple ANDing of a number of digital inputs is a necessary part
of this, but it is no longer enough.
Today's engineers who are now emerging from university or technical school are
moulded by a world of PCs, by communications and measured data, and by the
feasibility of what can be achieved with software and hardware.
Every graduate of a technical degree course today has at least some idea of what
programming in C/C++ means. And many have even done some programming
themselves and have learnt what possibilities and freedoms this language offers.
All of the central processing units of the IPC system, whether the mini controllers of the
IPC FEC or the Pentium CPU of the IPC PS1 Professional, are always a PC as well,
and as such can be programmed in C/C++.
The fact that this method of programming very much lends itself to many applications
such as gateways, user guidance, measured value processing etc. quickly becomes
quite clear. The fact that one family of controllers offers this possibility is unique. At
many points in this book there are reports of examples which are based on
programming in C/C++.

Our drinking water meets high quality standards – thanks to drinking water treatment,
Process control the filtering of drinking water, inspection, and much more besides.
systems, laboratory
technology and Pharmaceuticals or chemicals are subjected to the most careful testing before they are
hydraulic engineering brought into circulation. A single test is meaningless in this context. Hundreds,
thousands, or millions of tests are needed in order to obtain reliable findings.
Washing powder is supposed to ensure that our

washing emerges fresh and clean from the washing machine. How do the
manufacturers know what the formulation has to be in order to achieve the best
possible results? By an endless number of test wash cycles, all monitored, logged and
controlled by automation systems.
Process control engineering needs control loops, time, and repetition. The PC-based
systems of the IPC PS1 are ideally suited to tasks such as these.
In this section you will find a few examples from process control engineering. Enjoy
your read.
Process control systems, laboratory technology and hydraulic engineering 73

Many plants and systems used in water treatment have been implemented with the IPC
Water treatment PS1 system in recent years, and previously with the FPC 405.
Examples of these include:

_ Filtration plant for drinking water with a particularly interesting system for controlling
the Keystone flaps, which is implemented with an FPC405 software regulator and
Festo proportional valve.
_ Water flow regulation for filter cleaning
_ Air pressure regulation with fan for filter cleaning
_ Telemonitoring of process variables (pressure, temperature, flow rate)
_ Test station for Keystone fittings
_ Well control, telemonitoring, optimisation
_ Measured data acquisition system
_ Integration of control systems on the basis of the ViP process visualisation system
_ Integration of data into a database (production, distribution, maintenance ...)
_ Process visualisation with ViP WIN
_ Control of the aeration system, the water storage tank and the pumping stations
_ Control, monitoring and regulation of the entire water treatment works consisting of
wells, water treatment filtration plant (aeration, filtration plant with sand filter and
integration with the ozone block)
_ Filtration plant with carbon filter
_ Pumping station with water storage tank monitoring system and control room
_ Well control systems for various groups of wells over an area
_ Control of the pressure filter plants
_ Various filtration technologies are used, including sand filters, carbon filters (similar
to sand filters) and pressure filters.
The Novi Sad water treatment for example works underwent modernisation in 1996. The
filtration plant consists of 2 buildings, each with 12 sand filters. Each filter has an area
of 36 m2 and a flow rate of approximately 60 l/s. Altogether, the waterworks supplies
about 1500 l/s of drinking water.
Sand filter technology A sand filter works at its best when the flow through the filter is within defined limits.
One method of regulation is to measure the flow and control the flap for clean water.
Because of the geometry of the pipes, and due to a lack of space, this is not always
possible. Flowmeters are expensive. One alternative method is to measure the water
level in the filter. The level is kept constant. The geometry and diameter of the pipes
ensures that the untreated water is distributed evenly to all filters. Maintaining a
constant level means maintaining a constant flow.
74 Process control systems, laboratory technology and hydraulic engineering

Each filter has 6 Keystone flaps controlled by Festo valves for:
_ Untreated water
_ Clean water (controlled)
_ Sewer
_ First filtrate
_ Cleaning water
_ Air for filter cleaning
Control of the flap for clean water is carried out:

1. discontinuously with 5/3- or two 3/2-way valves
or
2. continuously with the proportional valve.
Control of water flow for

filter cleaning
Untreated water Clean water
Variant Advantages Nachteile

1 No analog outputs are High level of air consumption
necessary and manual and difficult to regulate
operation is easy to implement
2 Air consumption is low and Analog outputs are necessary
regulation is carried out
continuously
The control loops are implemented in accordance with variant 2, with good experience.
The regulators are stable. One controller controls 12 filters. A software regulator has 12
control loops. A mathematical model was specifically designed for this purpose. The
regulator parameters are optimised with technologists at the waterworks. The flaps
must not change position quickly because otherwise the water quality would
deteriorate. The parameters can be adjusted with the ViP process visualisation
system, which is also used to observe the behaviour of the control loop.
Optimum filter cleaning is achieved with a certain rate of water flow. The regulation
system was set up to ensure this. The operator can define the setpoint values for the
flow rate and the time (duration) in the ViP process visualisation system. A controller
with a software regulator assumes the function of the regulator. The values are stored
and later evaluated.

Sewer Water for filter cleaning
Sewer Fan
Air pressure regulation for Filter cleaning begins with the feeding of air from below. The rate of air flow is
filter cleaning regulated. Too much air can blow the sand out of the filter. The operator can define the
setpoints for the flap position and the time (duration) in the process visualisation
system. A controller with a software regulator assumes the function of the regulator. The
values are stored with an industrial data acquisition system and subsequently
evaluated.
Telemonitoring of process The distribution of water requires that the pressure and, if applicable, the flow should be
variables measured at various points and the values transmitted, visualised and stored.
The local stations are implemented with IPC PS1 modules. The data is transmitted by
telephone, over leased lines. The ViP process visualisation system is installed in the
dispatcher centre. A special-purpose communications driver takes over the data from
the remote stations. The collected data is displayed with ViP Trend2 and stored.
Test station for Keystone Before and after the Keystone drives are repaired, the customer would like to perform a
fittings test. A number of different parameters are measured. In addition, a service engineer can
test and adjust the limit switch.
Aeration for untreated The plant for aerating the untreated water comprises two buildings, each with two main
water pipes. The untreated water arrives with a flow rate of Q0 and a pressure of P0. The
regulator must maintain a constant pressure in four pipes. This ensures that the water is
evenly distributed and the plant operates at optimum efficiency. A controller and
software regulator are provided for the purpose of regulation. A PC with ViP for
visualisation and parameterisation of the plant is installed in the control room.

Q 11, P11
Q 12, P12
Q 0 , P0
Q 21, P21
Q 22, P22
Water storage tank control The level in the water storage tank is signalled to the pumping station and control
centre by radio. In the control room, this information is used for closed-loop control of
the entire system. Operation by remote control is also possible, and is used for
controlling the flaps or pumps. A separate IPC PS1 station is used for data acquisition.
A radio modem and radio transceivers are used for communications.
Well control The command centre for the wells is equipped with the system for remote control and
monitoring of the individual wells on the basis of the VIP software. BHD wells are
equipped with transmitters for water level, pressure and motor current, and with IPC and
Profibus communication modules.
Data is transmitted via Profibus. The command centre and the central control room are
linked by modem via dedicated lines.
Optimisation software analyses the values and presents the operator with a
recommendation as to what subsequent action needs to be taken.
Measured data A large number of measured values are gathered at the command centre. About 40
acquisition system analog signals are connected to a controller and are visualised and evaluated with a
ViP station. The PC with the ViP process visualisation is part of the network, and the
collected data is analysed and processed on various workstations.
Integration of control All of the control stations mentioned above should be integrated into one control
systems console. Water production (wells and the filtration plant) and distribution (pumping
stations, water storage tank and network) are integrated into a VIP WIN online database
system. All technical and real-time data is stored in one common database and is
made available to various workstations.
The maintenance team has its own workstation that

displays all alarms and preventive maintenance data. All information about pumps,
flaps and other devices is stored in the database. This makes maintenance work
easier, and increases the availability of the plant. The plant technologist carries out
process analysis at a workstation at which all online data, recorded operational data
and special-purpose calculation programs are available to him. Laboratory data is
entered manually, and evaluated together with the other data.
Keywords Proportional valves, waterworks, wells, filters, filter cleaning, flow rate, fans, Keystone
flaps, process control systems, telemonitoring, process visualisation, remote data
transmission via modem and radio, operational data acquisition

Many blue cheeses count as delicacies for the cheese connoisseur. And the mere
Ensuring cleanliness mention of a genuine Irish Cheddar is enough for some people to start salivating in
in cheese production anticipation.
After a little thought, however, it very quickly becomes plain that the maturing of cheese
from milk or the process of blue cheese "going mouldy" does not just happen
"somehow", but has to be carried out under reproducible, precisely defined conditions.
One external and necessary prerequisite for reproducibility and hence also consistent
quality is the cleaning of and maintaining the cleanliness of all pipes, tubes,
connections and valves. The requirements regarding cleanliness in the food sector are
immense. On the one hand this is a matter of the actual process of cleaning, which at
heart is a relatively simple form of sequence control. A series of process steps, starting
with flushing and proceeding through heating and the addition of various cleaning
agents, has to be worked through consecutively. A particularly critical task, on the other
hand, is checking and logging the results of the cleaning work. It is not enough simply
to go through the usual tasks one after the other, it is also of the very greatest
importance to check precisely that the cleaning work has indeed brought about the
desired result, and to record that fact.
An Irish cheese producer controls and monitors every aspect of cleaning the pipes and
tubes with the IPC PS1 Professional. In collaboration with Festo Ireland, the system
was set up in such a way that an IPC is responsible for each section of piping that
belongs together. A master computer collects the data via a fieldbus, and makes it
available to a process visualisation system. The process visualisation system is
responsible for recording and storing the process data. In addition, the operating
personnel at the central visualisation station are presented with a clear overview of all
process data.
Hardware The master computer is equipped as follows:

CP61 Festo fieldbus master
Software All of the IPC PS1s are programmed in FST, as is the master computer. The reason for
this is above all that it is very easy to program the actual cleaning process, as well as
the fact that it provides excellent support for the fieldbus and the Ethernet interface.
Keywords Food industry, process visualisation, Festo fieldbus, Ethernet, FST

The production of thermocylinders for thermostats in the automotive industry has been
Statistical process automated. The existing production machine, which operated semi-automatically, is
control in the now controlled by an lPC; this allows the production parameters to be changed easily
manufacture of when required. Because a 100% test is required at the end of the production process, a
thermocylinders test station was also automated with the aid of an IPC controller.
The test station performs a statistical analysis of the results of measurement of a

defined test variable, and in the event that the predetermined limit values are
exceeded, it proposes readjustment of the parameters in the production machine. In
addition, the measured values can be processed with a standard spreadsheet program.
The method of statistical process control implemented in this way ensures that the
level of production quality achieved is consistently high.
Storage of the test results ensures that the traceability required by the DIN EN ISO
9000 ff series of standards can be guaranteed.
Special features Separate programs have to be developed for the production station and the test station,
but these are networked and exchange data between each other. Standard software is
used on the test PC.
The advantages of a PC-compatible controller such as that provided by the PS1

system in a design created for a manufacturing environment are quite obvious in this
situation.
The production station essentially contains the digital inputs and outputs required for
controlling the production machine, together with an analog input module that enables
the production machine to be monitored:

CP70 Printer interface
DIS2 LCD display
In addition: printer and standard software package for analysis of the data.
Company: Dauphinoise Thomson, France
Keywords Statistical process control, quality assurance, DIN EN ISO 9000ff

In sewage treatment plants there is a large amount of operational data that needs to be
Data acquisition in monitored and visualised. In this application the IPC PS1 operates as an autonomous
sewage treatment data acquisition system alongside the control system for the sewage works as a whole.
plants
16 analog and 80 digital signals are recorded.
The analog signals are archived and statistically analysed.

The digital signals are evaluated as faults, counters or elapsed time meters.
The preprocessed data is passed to a visualisation system via an RS232 link.
Thanks to its rugged and modular design, its compact dimensions and its ability to be
programmed in high-level languages, the IPC PS1 is a highly suitable yet at the same
time cost-effective choice for decentralised data acquisition systems of this type. As
well as this, its low energy requirements are another obvious benefit in this connection.
Hardware A typical configuration consists of the following:

CP31 Serial interface (2 x)
ZP70 Printer interface
Radio-controlled clock with connection to RS232c
Printer
Software The engineering consultants Ingenieurbüro Katz, who were responsible for every aspect
of implementation of the system, used C/C++ as the programming language: above all
this offers flexibility in data management and the control of serial data transmission,
and is easy to use with the IPC PS1.
Keywords Data acquisition systems, statistical analysis, C/C++, sewage treatment plants, printer,
clock

System engineering GmbH Ilmenau is a company that uses the PS1 system in various
Controlling a configurations for solving a variety of problems. One of the most recent applications is
biological trickling the control of a biological trickling filter scrubber. This is a reactor built on a pilot scale
filter scrubber with the objective of removing hydrocarbon compounds from the exhaust air from
production plants by biological means.
The trickling filter scrubber consists of a cylinder, about

three metres in height, through which the air that is to be cleaned flows as well as a
flow of liquid to supply the biomass with water and trace elements. The bacteria
themselves are situated on carrier structures inside this cylinder.
In order to deal with the task in hand, about 20 analog and digital signals have to be
monitored, such as liquid levels, temperatures, flow rates of gas and liquid, and pH
values. The process is influenced by means of a variety of actuators: mass flow
controller, electrical and pneumatic valves and any number of pumps, the speeds of
which in some cases are controlled using frequency converters.

HC20 32-bit CPU, CF, flash
2 * IO11 8 x analog input module, current
IO12 8 x analog input module, voltage
CP3x RS232 interface
All sensors and actuators are electrically isolated from the IPC modules by coupling
relays or analog couplers.
Software The software used for the controller is a small process control system on the basis of
WinErs, software developed by engineering consultants Ing.-Büro Dr.Schoop. The
drivers for this were developed at SEI. In addition to the possibility of allowing graphical
planning of the controller, this system also provides modules for data acquisition,
archiving and visualisation. The installation is operated from a PC running Microsoft
Windows, which is connected to the IPC either via a null modem cable, a modem or
Ethernet. This means that monitoring can also be performed from a remote location. In
standalone operation without an operating computer, the accruing measurement data is
buffered in the IPC's CPU for up to several days. Various operating modes are run
through automatically (startup, cleaning, operation), while control in manual mode is
also possible.
The illustration shows part of the control system as a
sequencer. In this way, WinErs can be used both for programming and later for
visualisation of the control system.
Part of the control system

as a sequencer
Keywords Biological exhaust air purification, level measurement, temperature measurement, flow
rate, pH value, process control, telemonitoring

Of course you know that "plastic" is not degradable. This is why we have recycling
Determining the markings on packaging, why we segregate different types of waste, why there is an
cell state of ongoing discussion on replacing plastic packaging with paper packaging, for example.
microorganisms In the meantime, however, biologically degradable types of plastic have been
developed. These are produced, for example, by microorganisms (such as bacteria)
"eating" raw materials and in so doing converting them into types of plastic which in
turn can be decomposed by other bacteria.
What does the "cell state" The microorganisms are alive – a prerequisite for them being able to "work" at all. The
tell us? degree of well-being of these organisms can be identified from their consumption of
oxygen – in much the same way as with us humans. When we are fit and producing our
top performance we consume more oxygen than when we are worn out and tired.
On the basis of the level of oxygen consumption, therefore, it is possible to draw direct
conclusions as to the productivity of the system. Measurement of the oxygen provides
information on the progress of production, on the speed of production and finally on
whether production is completed – this is because at some time or other the bacteria
will start to consume the desired end product. After all, it is biodegradable.
In addition to the use of oxygen measurement within the production of materials, this
method of measurement can also be used to establish whether bacteria are capable of
decomposing certain materials: contaminated soil, mixtures of chemicals and many
other similar substances can be selectively fed to bacterial cultures to be "eaten" – the
bioactivity sensor determines whether the bacteria are able to eliminate the
contaminants.
What does the PS1 The core of the system for determining the cell state is an oxygen electrode. The
system do? electrode requires a defined voltage supply and a specific method of signal
conditioning. An independent input module was developed specially for this purpose,
and was integrated into the IPC PS1 system.
In order to obtain a meaningful analysis of the data from the oxygen electrode, a
powerful computer system is required. The program must be structured in such a way
that the test can be adapted to a range of different tasks. After the system has been
configured, the data has to be logged, stored and displayed. This is where the
openness of the PC is ideal. At the same time, it should be possible to put the system
to use directly in production or in mobile laboratory systems, which is why suitability
for industrial use was called for. The compact IPC PS1 is therefore an obvious choice.

Hardware HC15 PC/CHIP CPU, EPROM, RAM
OM74 16-bit relay output module
OM70 6-bit relay output module with max. 8A switching capacity for direct control
of the pumps
IPC-OXi Company-developed analog module for the oxygen electrode
The IPC-OXi module:

Electrode bias voltage: -500 to -900 mV
Measured current: up to 10 µA. Variable adjustment of the gain with
external potentiometer
Operating voltage: 12 to 36 V from the PS1 busboard
Output voltage: 0 to 10 V
Power demand: approx. 1 W
Connection of 2 Clark electrodes per module
Software Programming was carried out in C/C++ with the aid of the Borland C compiler. First a
program flowchart is drawn up by hand for the purpose of program planning, and this is
then converted into C code. The Quinn-Curtis library is used for visualisation of the
measured values.
Keywords Measuring bioactivity, Clark electrode, bacteria

Diehl Automation GmbH produces the entire control system for the first mobile filling
Filling up with liquefied station for liquefied natural gas (LNG) in Germany, on the basis of the PS1 system.
natural gas
Liquefied natural gas is one of the energy options of the future for traffic on our roads.
LNG is based on natural gas, the stocks of which according to today's understanding
will last longer than the stocks of mineral oil. The essential advantage of using LNG in
internal combustion engines is that an LNG-powered engine emits 80% less carbon
monoxide (CO) than a petrol engine and 60% less than a diesel engine. Oxides of
nitrogen (NOx) are reduced by 65% and 80% respectively, while benzene and soot
particles are not produced by LNG engines at all; the generation of ground-level ozone,
the cause of summer smog, is reduced by 60%. LNG therefore stands out because of
its environmental friendliness – in comparison with traditional petrol or diesel engines.
The temperature of LNG is –161° C; it is in the liquid state at this temperature, and
must be stored in appropriately isolated tanks.
Mobile LNG tank
The mobile filling station that was developed and built for Messer Griesheim GmbH is
designed to deliver supplies of LNG for vehicles which are intended to prove the
suitability of LNG engines in real, everyday use.
Diehl DAS 5 Diehl Automation calls the control system DAS5. The basis for the hardware is
provided by the IPC PS1 with analog and digital I/Os in conjunction with
communication to a control system via a modem. The software uses the RT kernel to
create a real-time-capable multitasking system. Building on this, function blocks were
written for all functions of the filling station. This modular software concept makes for
easier maintenance and troubleshooting. This is because the individual functions such
as cooling, filling the tank, refuelling vehicles etc. are each provided as separate
modules.

Sending a log fax by A GSM modem connected to an RS232 interface sends a log fax about every refuelling
modem and filling operation to the central control desk at Messer Griesheim. As a result,
Messer Griesheim always has an up-to-date overview of the operational status of the
LNG filling station.
The control cabinet

mounted on the truck
PS1 configuration BP40 14-slot busboard

HC27 486 CPU
CP30 Additional COM2 (for terminal) and COM3 (for GSM modem)
MC10 PCMCIA interface (for program updates via SRAM card)
AS11 Pushbuttons and LEDs for maintenance
x IM11 16 digital inputs
OM40 16 digital outputs with connection to Festo CPV valve terminals
OM70 6 relay outputs
IO11 8 analog inputs
Keywords Filling station, remote data transmission, fax, RT kernel, GSM

Water is the stuff of life. Drinking water is a vitally essential commodity. The quality of
Providing for clean the drinking water provided must be healthy and pure. The PS1 system helps to
water safeguard the supply of drinking water.
Water comes out of the tap and disappears down the plughole. That's all. Have you
ever stopped to think about everything that is necessary to maintain the cycle of water
extraction, water distribution, water disposal and water purification? Hardly any of us
step back to give this any thought any more. To make sure that we don't have to think,
other people have done some serious thinking – and have used the PS1 system.
Wells by the Danube The extraction of drinking water in the vicinity of rivers is often based on the use of
wells. The wells, which may be more than 100 m deep, draw groundwater that has been
filtered through the sand strata in the area alongside the river. The water is pumped to a
water treatment plant, which removes contaminants which have not been trapped by the
natural sand filtering, and is finally pumped to the consumers.
In order to supply a mid-sized city of around half a

million inhabitants, dozens of wells are required. Every well represents a considerable
investment. It is generally the case that entire families of wells are built. Often this
means several "small" wells being arranged around a "larger" well. The way in which
the water is drawn from the well is one of the decisive factors in the longevity of a well.
If the well is constantly pumped empty, to the very limit, this is just as damaging as if it
is not used at all for a long period of time. The role of the PS1 system is to optimise
water extraction with this in mind.
Remote maintenance Festo Austria has supplied and installed the entire set of remote maintenance and
telemonitoring equipment for well installations of this type. A well installation
consisting of about 10 wells extending over an area totalling perhaps 5 km in diameter
is combined to form a single group. Each individual well is "taken care of" by an IPC
PS1. The wells are networked with each other by means of Profibus FMS, and the data
is collected in a separate IPC PS1 for each group. A small local control console
belonging to the group of wells includes a standard PC, where visualisation of the group
is provided on site with the aid of VIP, the process visualisation system from Festo
Austria.
Functions for telemonitoring, remote diagnosis, remote control and data acquisition are
all implemented on the control console.
The group IPC is connected via a modem to a higher-level control station that enables
all of the groups of wells to be brought together under one umbrella and visualised
accordingly.
As a result, in the specific project we are referring to here, in Novi Sad, it is possible for
the first time to view and manipulate well parameters from a central control room with
the aid of VIP, the visualisation of industrial processes.

Well control Every well is assigned its own IPC, which operates autonomously to ensure optimum
control of the pumps for the well. To help it do this there is a system of sensors that
provides information about the water level, pressure, flow rate, electricity consumption,
pump parameters etc. The electrical parameters of the three to four pumps for each well
are monitored by a separate measuring device. These measuring instruments are
connected to a PS1-CP30 via an RS485 interface. Networking with the other stations
and the control console is via Profibus FMS.
Environmental conditions The unusual situation of a well installation requires special protective measures for the
electronics. Above all, there are three particular aspects that are important:
Firstly, the immediate surroundings of the well are cooled to a large extent by the water
extracted from deep in the earth. In winter, though, it can become bitterly cold and
damp. For that reason, all of the control cabinets are heated.
Secondly, in a distributed system of this nature it is quite possible for the power supply
to fail fairly frequently. Consequently, an uninterruptible power supply is fitted in the
control cabinet for each local control console; this safeguards the power supply for a
period of roughly 15 minutes. That is enough time to be sure of informing the control
centre that the power has failed.
Thirdly, in a system that is spread out over distances of several kilometres there is a
risk of lightning strikes on the connecting lines. To counter this, all sensors are
decoupled by means of surge voltage protectors, the actuators are controlled with the
aid of relays and the Profibus is run via fibre optic cable. A converter from RS485 to
fibre optic cable is provided for this purpose at every station.
The overall effect of these protective measures has stood the test excellently in
practice.

A control cabinet with a
heater
Hardware Example of a PS1 configuration:

HC16-F CPU
I048 Analog input module
IM11 Digital input module
OM21 Digital I/O module
CP61 Profibus FMS module
CP30 with RS485
Software The systems are programmed with FST software. One of the key reasons for choosing
the FST software was the openness of the software for additional drivers. For example,
an external firm of engineering consultants, being familiar with the driver interface for
the FST software, wrote a driver for the RS485 interface to the measuring devices and a
driver for controlling the modems. To this must be added the fact that the Cl, the
interface for troubleshooting, is so simply designed that a large range of software and
devices are very easily able to access systems programmed with FST.
Keywords Well control, pump parameters, telemonitoring, remote diagnosis, RS485, Profibus,
process visualisation, lightning protection, environmental conditions

Have you ever driven a formula 1 racing car? Did you think it was out of the question?
Edutainment and Well, perhaps you can after all. Because advanced simulation technology, which was
simulation previously only available for the training of aircraft pilots, has now found its way into
much more widespread use. Pneumatic or hydraulic drives, sophisticated control
technology, video sequences which allow the depiction of every road from every
viewing angle – all of these are already in use today. One aspect is the excitement and
fun to be had in a simulated car race, but there is also the possibility of imparting
knowledge, for example in museums. In those applications, figures and images are set
in motion in order to make history and literature come to life and be easier to learn.
In this section you will find a few examples of edutainment applications using the very
latest automation technology. Have fun reading about them.
Edutainment and simulation 91

How can history be made into something that can be experienced, or even sensed and
Discoveries on the felt as if at first hand? What does it actually mean when we hear and read about
high seas seafarers who went on voyages of discovery many years ago?
At the Heureka science museum in Finland, an attempt has been made to answer this
question using modern simulation technology. In 1878/79, the explorer Adolf Erik
Nordenskiöld and his crew were the first to traverse the Northeast Passage in his ship
the "Vega". A reconstruction of the forward section of the "Vega" is on show at the
Heureka science centre, mounted on a pneumatically driven platform. The system is
set in motion by means of an intelligently arranged cylinder combination in such a way
that people standing on it are given the impression of being on a ship on the high seas.
Within the controller's multitasking system, each cylinder has a separate program
dedicated to it which controls the valves. Each cylinder can be set individually, with
the settings ranging from storm to calm seas, and from light waves to full sail. A truly
impressive experience.
The octahedron of the pneumatic cylinders and the associated controller are designed
in such a way that they can create motion in all sorts of different models. As a result,
92 Edutainment and simulation

Heureka is making the simulation technology itself an exhibit of the museum: a small
model of a ship, about 1 m long, uses exactly the same simulation technology as the
"Vega", only on a smaller scale. This is learning about history and technology by
sensing it and experiencing it.

HC16-F PC/CHIP CPU, EPROM, flash, FST kernel
OM22 Digital input/outputs, each 16-bit
Software FST, the multitasking programming system, can provide a separate task for every
cylinder.
Keywords Edutainment, simulation

Usually, as we know from many examples in our experience, a zoo keeps animals in
Keepers in the wild cages or artificial enclosures, behind glass or fences. The Victoria Open Range Zoo in
Australia takes a quite different approach. There the animals are allowed to run free as
if in the wild. Over an area of about 200 hectares, the animals have a habitat at their
disposal that is left in its natural state.
Visitors to the zoo can go out and observe the animals on a safari tour. To do this, they
travel in large, air-conditioned buses. To a certain extent, therefore, in this case it is the
human visitors who are sitting behind glass, while the animals live in the open.
In order to make visiting this zoo safer and more comfortable, Rambler Concept
Vehicles has developed a safari bus in which giant windows can be opened and the
doors can open up the entire side of the bus to allow people to get in and out.
Because of the large forces involved, the doors are driven with hydraulic cylinders,
while the windows are moved by very slimly built DNC cylinders. The panorama side of
the bus is controlled by an IPC FEC, which obtains its electrical supply directly from
the 24 V system available on the bus.
A particularly ingenious feature is the way the window cylinders are controlled, for
example. They are moved carefully with their own low-pressure circuit until they are
finally fully closed at the end under normal pressure.
Hardware IPC FEC FC20 Mini controller with AM186 processor
Software FST
Keywords Vehicle technology, door control, tour bus

At the vocational training school in Hamburg, a group of teachers have got together to
Learning to use enable them to give practical instruction in modern automation technology. Two things
modern automation had to be done to make this possible.
technology
Firstly, the teachers sat down with trainees to develop dynamic models that can be
used for practising programming, commissioning and troubleshooting. And secondly,
the school bought controllers which can be programmed according to the international
standard IEC 6 1131-3, and which can also be networked with Ethernet – both IPC PS1
systems and IPC FEC Compact controllers.
In a second phase, the controllers will also be used as PCs in information technology
lessons, which means that IT in general and programming in C/C++ or Pascal will not
be seen merely as theoretical toys but as tools that can be put to practical use.
Hardware IPC FEC FC34-MWT the mini controller with Ethernet, programmable with
MULTIPROG
IPC PS1 with HC02 CPU and various analog and digital input/output
modules
Software MULTIPROG, C/C++
Keywords Vocational training, networking

96
The IPC@CHIP® is considered to be the world's smallest industrial PC. Even if
Applications with the superlatives such as these are always questionable, the combination of processor
IPC@CHIP technology, memory, flash memory for the safe storage of applications and data even in
the event of a power failure, serial interface, Ethernet network and access to the
input/output level in a single chip is a quite outstanding technical gem. Although the
first chips were only delivered as recently as November 1999, just a year later there are
finished products on the market with quite exceptional qualities.
Although the independent development of automation

systems by individual companies is not the main concern of this little book, the
IPC@CHIP and its applications are so directly involved in automation technology that
they are worthy of a place here.
In this section you will find a few examples of applications with the IPC@CHIP. Enjoy
your read.

CAN is an unusual and special type of fieldbus. Because of its origins in automotive
Ethernet - CAN gateway engineering, it is optimised for a high standard of reliability in data transmission, fast
responses and relatively short transmission distances. The CAN bus has been
successfully introduced in many applications, and thanks to its particular qualities it is
well established. Increasingly, though, the data from these CAN-based applications is
also coming to be required in local networks. Nowadays, however, these networks are
almost always Ethernet networks.
Two companies, Port GmbH and EMS Wünsche, have got together to develop an
Ethernet - CAN gateway to deal with this problem. The gateway ensures that the CAN
bus can operate without interference, while the data is made available in the Ethernet
network.
Inside the EtherCAN_186/RMD there is an IPC@CHIP doing its stuff on the Ethernet
side, and on the CAN side a Full-CAN processor.
One notable fact about the EtherCAN module is that it was developed in its entirety
within 5 months of the first delivery of the IPC@CHIP. On the one hand this proves the
degree of know-how available to the development team from Port and EMS, but at the
same time it illustrates the simplicity with which the IPC@CHIP can be put into service
if the people involved have knowledge of programming PCs.
Hardware IPC@CHIP SC12
Software C/C++ is the programming language of choice for applications of this type.
Internet http://www.port.de
Keywords CAN, Ethernet

!ASCO is a system house in the field of weighing and metering technology which has
Controlling with the developed a universal basic printed circuit board with the IPC@CHIP for its own
IPC@CHIP applications and those of its customers.
Depending on how it is equipped, the printed circuit board can be used either as a low-
cost microcontroller or an embedded PC.
Optiterm, as the board is named, is ideally suited to carrying out control tasks in the
!ASCO load cells, recording measured values and making the data available on the
network for further processing.
Software C/C++
Internet http://www.asco-online.com
Keywords Weighing technology, measuring technology, network

The vocational academy or Berufsakademie (BA) in Mosbach offers courses leading to
Learning with the a qualification as Dipl.-Ing (BA) in a variety of subject areas. In the subjects of
IPC@CHIP electrical engineering, information technology and mechatronics, the IPC@CHIP is
used for course work and project work.
The aim is that the students should gain experience in the development of printed
circuit boards with microcontrollers (hardware) and in the programming of such systems.
With the IPC@CHIP, it is also possible at the same time to bridge the gap to the study
areas covering automation engineering and network technology. To help to do this, an
experimental printed circuit board was developed with the IPC@CHIP at BA Mosbach.
All of the data relating to the printed circuit board is public, which means that the
students can use it as the basis for their own developments.
Software C/C++ is the programming language for the engineer.
Internet http://www.ba-mosbach.de
Keywords Engineering studies, experimental printed circuit board, training and further education

Rittal is one of the world's largest manufacturers of control cabinets. Many control
Monitoring with the cabinets are used in computer centres, where monitoring the availability of the
IPC@CHIP computer systems is a matter of crucial importance. This is why Rittal has had the
CMC developed (short for Computer Monitor Control), which incorporates a control
cabinet monitoring facility. The variables that are monitored include the temperature in
the control cabinet, for example, but also vibration, which provides an indication that
someone is attempting to open the control cabinet by force. The CMC is integrated into
the network, so the monitoring data can be retrieved via the network both locally and – if
required – via the Internet or through a modem.
The centrepiece of the CMC is the IPC@CHIP, which is

the ideal choice for establishing the link between the sensor signals for monitoring and
the network technology.
Software C/C++ is the language of the computer world.
Keywords Control cabinet, monitoring, CMC

All of the applications in this book are closely tied to the IPC system from Festo and
Hardware Beck. A whole family of central processing units allows the creation of automation
systems which are all characterised by the fundamental philosophy of the IPC family.
IPC@CHIP®
IPC FEC® Compact
IPC FEC® Standard

IPC PS1®
_ All systems are PC-based at their core. This means that essentially every CPU can
also be used as a DOS computer (or in the case of the 32-bit CPUs also as a
Windows computer). Most of the applications are descriptions of PLC applications,
though. Nevertheless, the PC core is always there in the background, because it is
this that opens up the possibility of easily linking with important state-of-the-art
functions such as Ethernet networking, file handling, flexibility in the use of drivers
and modules, and much more besides.
_ All systems are small – in relation to their performance capability extremely small.
Whether or not the IPC@CHIP® is in fact the world's smallest industrial PC, every
CPU is representative of the claim in its performance segment to build small, to
enable the use of small control cabinets, to save space and energy – and in this
respect is a world champion.
_ All systems are network-capable. Every CPU can be equipped with Ethernet, every
CPU – even the smallest – can be programmed via Ethernet and communicate via
Ethernet. Advanced automation technology needs the Ethernet network – all of the
CPUs in the IPC FEC range as well as the IPC PS1 range support Ethernet.
_ All systems are PLCs as much as they are PCs. Tens of thousands of CPUs are
used in the same way as traditional PLCs with the PLC programming languages.
And just as many systems could not do their job without the link to the PC world.

104
Agriculture ........................................................................................................................20
Index ASi....................................................................................................................................34
A Assembler ........................................................................................................................44
B Basic ..........................................................................................................................45, 65
Boolean Algebra...........................................................................................................9, 72
C C/C++.........................................................7, 17, 21, 29, 34, 43, 44, 53, 55, 59, 61, 62, 63,
..........................................................................67, 69, 70, 72, 81, 85, 95, 98, 99, 100, 101
CAN ..................................................................................................7, 8, 21, 34, 68, 69, 98
Checkbox ..................................................................................................7, 16, 17, 60, 61
CIM .................................................................................................................................. 42
Clark Electrode................................................................................................................ 85
COMX........................................................................................................................ 52, 87
E Edutainment ...........................................................................................................8, 91, 93

Ethernet .............................................................5, 8, 23, 30, 31, 34, 35, 36, 37, 44, 47, 49,
........................................................................................53, 64, 71, 79, 83, 95, 97, 98, 103
Excel ............................................................................................................................... 57
EXOR ............................................................................................................ 19, 20, 30, 31
F Fax .....................................................................................................................................4
Flash ....................................................................................................................43, 44, 67
FST ............................................................................ 7, 11, 13, 15, 18, 19, 20, 23, 30, 31,
................................................................................... 32, 33, 34, 37, 41, 47, 79, 90, 93, 94
G Gateway ...........................................................................................................................43
GSM ...............................................................................................................21, 46, 54, 87
H Hall Sensor.................................................................................................................58, 59
Handling .....................................................................................................................12, 13
I Internet..................................................................................7, 34, 35, 47, 98, 99, 100, 101

IPC FEC
FC20................................................................................................................... 11, 94
FC30......................................................................................................................... 39
FC34............................................................................................................. 36, 37, 47
FC38......................................................................................................................... 46
IPC PS1 module
AM11 ............................................................................................................ 15, 24, 57
AM20 ........................................................................................................................ 29
AS11............................................................................................................. 47, 59, 87
BG10 ............................................................................................................ 56, 68, 69
BG20 ............................................................................................................ 27, 60, 61
BP11........................................................................................... 13, 27, 45, 47, 53, 55
BP31........................................................................................... 19, 41, 43, 44, 69, 90
BP40................................................................... 20, 21, 24, 27, 30, 59, 79, 81, 83, 87
BP50............................................................. 15, 17, 44, 53, 57, 61, 62, 67, 70, 80, 93
CP10................................................................................................................... 27, 53
CP11......................................................................................................................... 64
CP12......................................................................................................................... 44
CP14............................................................................................................. 30, 47, 79
Index 105
I IPC PS1 module
CP30..........................................................................20, 52, 53, 55, 59, 67, 69, 87, 90
CP31............................................................................................................. 41, 62, 81
CP3X ........................................................................................................................ 44
CP61....................................................................................................... 20, 30, 79, 90
CP70................................................................................................................... 62, 80
CP81......................................................................................................................... 69
DIS 2......................................................................................................................... 70
FC/FD10....................................................................................................... 41, 59, 70
FD10......................................................................................................................... 25
HC01............................................................................................................. 18, 19, 44
HC02................................................................................................................... 23, 95
HC12............................................................................... 24, 52, 53, 55, 62, 63, 64, 80
HC15................................................................................................................... 45, 85
HC16......................... 13, 15, 20, 21, 23, 27, 30, 41, 47, 56, 60, 61, 70, 79, 81, 90, 93
HC17......................................................................................................................... 57
HC20....................................................................................................... 44, 54, 55, 83
HC27............................................................................................................. 27, 69, 87
HC50......................................................................................................................... 54
HD50......................................................................................................................... 59
HD51......................................................................................................................... 43
IM10................................................................................ 13, 20, 21, 56, 63, 64, 80, 81
IM11.......................................................................... 19, 27, 30, 41, 43, 79, 83, 87, 90
IM12.......................................................................................................................... 59
IO10............................................................................................ 15, 61, 62, 79, 80, 93
IO11........................................................................................................ 63, 81, 83, 87
IO12............................................................................................ 20, 21, 57, 59, 83, 85
IO40.......................................................................................................................... 67
IO41.......................................................................................................................... 70
IO60.................................................................................................. 21, 27, 61, 83, 93
IO70.................................................................................................................... 64, 70
MC10 ................................................................................................ 45, 52, 53, 55, 87
OM10........................................................................ 13, 20, 21, 56, 63, 64, 70, 80, 81
OM11.................................................................................... 19, 23, 27, 30, 43, 59, 79
OM12........................................................................................................................ 83
OM20.................................................................................................................. 45, 57
OM21.......................................................................................... 15, 17, 44, 67, 69, 90
OM22............................................................................................................ 59, 61, 93
PS10............................... 19, 20, 21, 24, 27, 30, 41, 43, 44, 56, 64, 69, 79, 81, 83, 90
PS11......................................................................................................................... 59
SM14 ........................................................................................................................ 53
ZL31 ................................................................................................................... 53, 55
ZP11......................................................................................................................... 55
IPC@CHIP................................................................. 8, 47, 97, 98, 99, 100, 101, 102, 103
DK40......................................................................................................................... 47
SC12................................................................................................... 98, 99, 100, 101
L LNG ............................................................................................................................86, 87
M Modem............................................................................................................39, 41, 45, 55

MULTIPROG..................................................................................7, 27, 48, 49, 50, 67, 95
Multitasking..................................................................................................................... 33
106 Index
N Novell ...............................................................................................................................64
P Packaging technology .....................................................................................................11

Pascal ..........................................................................................25, 56, 57, 64, 67, 71, 95
PLCOpen......................................................................................................................... 48
Positioning .......................................................................................................... 15, 29, 57
Profibus ............................................................................................. 23, 34, 77, 88, 89, 90
Q Quality....................................................................................................................7, 24, 64
R Random ............................................................................................................................31
Real-Time.........................................................................................................................44
RS232.................................................................. 20, 27, 45, 53, 55, 57, 59, 69, 81, 83, 87
RS485............................................................................................................ 44, 63, 89, 90
Rubber ............................................................................................................................. 66
S S5 ...............................................................................................................................29, 59
Sawmill.............................................................................................................................29
Scall ................................................................................................................................ 45
SPC200 ..................................................................................................................... 30, 31
T Telemonitoring ...........................................................................................................74, 76
V Valve terminal ..................................................................................................................20

VIP..................................................................................................................77, 78, 88, 89
Visual Basic.............................................................................................................. 23, 39
W Water ..........................................................................................................8, 74, 77, 78, 88

WEB Server......................................................................................................................34
Welding ..................................................................................................................... 15, 62
Windows NT........................................................................................................ 39, 42, 43
Index 107
108 Index

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328,5 mm 8,5 mm 120 mm 42 mm

Plagemann IPC recipe book

IPC recipe book

IPC recipe book

© 2004 by Festo AG & Co.

_ small and maintenance-free, to allow smaller control cabinets to be used

Wetzlar, October 15, 2000

Networking and remote maintenance ......................................................................35

Measurement technology, data processing and quality assurance..................51

Edutainment and simulation.......................................................................................91

Applications with the IPC@CHIP ................................................................................97

Control and handling technology 9

The Boxer from the Rembrandt Packaging company in

10 Control and handling technology

Keywords Packaging technology, cardboard box, sequence control

Control and handling technology 11

A major German manufacturer of handling devices for injection moulding machines

Sprue removal device

12 Control and handling technology

The key components of the handling system are the following:

_ The y-axis is arranged perpendicular to the ejection system; a pneumatic linear

Hardware BP11 3-slot busboard

Keywords Handling system, injection moulding, step programming, positioning

Control and handling technology 13

14 Control and handling technology

Hardware BP50 5-slot busboard with power supply

Keywords Welding, stepping motor, positioning, mobile application

Control and handling technology 15

16 Control and handling technology

Hardware Example configuration

Keywords Image processing, shaker, Checkbox

Control and handling technology 17

Particularly in the textile sector, international competition is extremely tough. For a

Of course it is not a problem to build automatic sewing

18 Control and handling technology

Hardware BP31 8-slot busboard

Control and handling technology 19

Hardware BP40 14-slot busboard

Keywords Agriculture, silo, pneumatic cylinder position detection, touch panel

20 Control and handling technology

Hardware BP40 14-slot busboard

Optional CAN interface

Control and handling technology 21

Pick & Place Unit s

Points Point s Poin ts

Tes t Tes t Test

On first impression, that sounds nothing special: transfer – transport – transfer –

22 Control and handling technology

Hardware The pick-and-place units consist of the following:

The sorting gate controllers consist of:

Control and handling technology 23

BP40 14-slot busboard

PS1-IM10 16-bit digital input module

24 Control and handling technology

Keywords Capacitor manufacture, quality requirements, stepping motor, InterBus, Pascal,

Control and handling technology 25

26 Control and handling technology

A separate CPU for operator guidance - the human-machine interface - is

Control and handling technology 27

28 Control and handling technology

Keywords Sawmill, positioning, S5, C/C++

Control and handling technology 29