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Prolog-factory

Manual

Order-NR.:
Type:

Manual prolog-factory

Designation

Prolog_Manual_A005.doc

Printed:

August 13

Autor:

Schober

Graphics:

Schober

Layout:

Schober

© Festo Didactic GmbH & Co.KG., D-73770 Denkendorf, 2013
Internet: www.festo.com/didactic
e-mail: did@festo.com
This manual, all text and illustrations included, is protected by copyright. Any utilization outside the
limits of the copyright law and other than training purposes are not permissible without our definite
approval. This applies in particular to reproductions, operations, translations, micro filming and the
storing and processing into electronic systems. Parts of this manual may be copied by the authorized
user, exclusively for teaching purposes. Distribution of this documentation, as well as reproduction,
use and spread of its contents is prohibited, insofar not permitted explicitly. Offences are liable to
compensation. All rights reserved, especially the right to execute registrations concerning patents,
designs for use and patterns.

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© Festo Didactic GmbH & Co.KG. • prolog-factory

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Intended use

The User Manual must be to hand at all times. Keep it close to the machine.

This installation was developed and manufactured only for use in basic and further
training in the fields of automation and communications. The training company
and/or the training staff must ensure that the trainees observe the safety
precautions described in the accompanying manuals.
Furthermore this manual describes setup and possible uses of the singular stations.
It contains all information and data required for commissioning, maintenance and
operation.
Festo Didactic accepts no liability for injury or harm to trainees, the training
company and/or any third parties occurring when the installation is used for any
purpose apart from training, except Festo Didactic has caused such injury or harm
intentionally or by grossly negligence.

The manual is divided into four parts:
Part A
In addition to technical data, Part A contains an overview of the possible uses of
the stations.
Part B
Part B contains some exercises and the solutions for this exercise (Not available
for each station).
Part C
Part C contains the pneumatic and electrical diagrams for the station and the
listing of the control programs (Not available for each station).
Part D
Part D contains data sheets and technical information about the electrical and
electronic modules used.

© Festo Didactic GmbH & Co.KG. • prolog-factory

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At this point we would like to point out that this manual and the concept of the operating instructions for a Flexible Training System of this type are regularly updated.Terms and explanations in conveying and handling VDI 2860 .terms VDI 2861 .Technical safety requirements concerning automated production systems VDI 2411 . The installation was designed in such a way as to keep the number of wearing parts to a minimum. DIN EN 292 -Machine safety DIN EN 60204 . the System is maintenance-free.See DIN EN 60204 DIN 40719 . This does not include machines that are part of optional expansions (such as industrial robots). either in writing or via telephone: +49(711-3467-0) 4 © Festo Didactic GmbH & Co.KG.characteristic quantities DIN 19245 . All bearings are lubricated for life. electrical and safety-engineering design and production. you would help us a great deal by passing on your suggestions for improvement.Electrical equipment of industrial machines DIN VDE 0113 . • prolog-factory .Assembly and robotics . To ensure that the instructions are ever more user-friendly. equipping and operation of industrial robots VDI 2853 . Please let us know of your suggestions.Assembly and robotics .Circuit documentation VDI 2853 .Technical safety requirements concerning the building.List of applicable standards and regulations The list below provides an overview of the most important standards and regulations relating to mechanical.PROFIBUS Part 1-3 As far as possible. corrections or ideas.

7 Intended use __________________________________________________ 28 2.2.4 Pick and place station ______________________________________ 16 2.Contents 1 Intended use _______________________________________________________ 3 2 Introduction ______________________________________________________ 11 2.2.2.2.5 Duty of trainees _______________________________________________ 27 2.KG.11 Robotino 1&2 _____________________________________________ 23 2.2 Testing station with color sensor _____________________________ 14 2. • prolog-factory 5 .2.8 Important notes _______________________________________________ 29 © Festo Didactic GmbH & Co.5 Fluid muscle station ________________________________________ 17 2.9 Commissioning station _____________________________________ 21 2.3 Didactic structure ______________________________________________ 24 2.3 Processing station _________________________________________ 15 2.4 Duty of the operating authority ___________________________________ 27 2.2.2.6 Storing station ____________________________________________ 18 2.2.1 Triple stack magazine station ________________________________ 13 2.2 Customer system ______________________________________________ 12 2.1 General ______________________________________________________ 11 2.8 Sorting station ____________________________________________ 20 2.7 Separating station _________________________________________ 19 2.2.6 Warranty and liability ___________________________________________ 28 2.10 Log area__________________________________________________ 22 2.2.2.

2.2 Personnel ____________________________________________________ 34 3.1.4 Dangers due to pneumatic energy ____________________________ 33 3.KG.1 6 Safety symbols ____________________________________________ 35 Pneumatic commissioning___________________________________ 41 © Festo Didactic GmbH & Co.3 Emergency stop system _________________________________________ 34 3.2 Safety precautions in standard operation ______________________ 32 3.1 4.1.1.1.1.6 Organizational measures ____________________________________ 33 3.3 Outside training operations _________________________________ 34 3.2.2 Scope of delivery __________________________________________ 37 4.2.1 Notes on personnel ________________________________________ 34 3.Contents 3 General safety instructions __________________________________________ 31 3.1. • prolog-factory .3.3 General information ________________________________________ 38 Commissioning ________________________________________________ 41 4.2.1 Unpacking ________________________________________________ 37 4.5 Maintenance – Servicing – Malfunction removal _________________ 33 3.3 Dangers due to electric current _______________________________ 32 3.2 Set up _______________________________________________________ 38 4.1.1 Transport _____________________________________________________ 37 4.1.2 Training operations ________________________________________ 34 3.3.1 Handling the system____________________________________________ 31 3.1 4 Commissioning ____________________________________________________ 37 4.1 Dangers in handling the machine _____________________________ 31 3.

Contents 5 4.5.2 Electric commissioning _____________________________________ 41 4.7.3.3.7.2 Start up log area ___________________________________________ 73 © Festo Didactic GmbH & Co.1 General operation notes ________________________________________ 47 5.3.1 Explanations ______________________________________________ 67 5.5.1.3.4 Program start _________________________________________________ 56 5.3 Switch off the robotino _____________________________________ 55 5.2 Start up __________________________________________________ 54 5.2 Operation rules ____________________________________________ 47 5.2 Sequence to collect one Palette ______________________________ 67 5.2 Process description ____________________________________________ 48 5.3 Global Variables ___________________________________________ 69 5.3 Material flow ______________________________________________ 49 Robotino information and operation ______________________________ 51 5.1.2.3 Connecting communication cables ____________________________ 42 Operation ________________________________________________________ 47 5. • prolog-factory 7 .KG.1 General __________________________________________________ 52 5.1 5.5.3.6 Data Exchange Variables ________________________________________ 70 5.6 Program Upload robotino __________________________________________ 57 5.1 Behaviour rules ___________________________________________ 47 5.5 Robotino-Pro-Log ______________________________________________ 65 5.1 General __________________________________________________ 71 5.7 Log area information and operation _______________________________ 71 5.

11 MES Mode ____________________________________________________ 78 WINCC ___________________________________________________________ 79 6.2 7 Use Runtime Application ________________________________________ 80 MES Software _____________________________________________________ 87 7.1 8 Start-up WINCC ____________________________________________ 79 Standalone mode of Distributing Station______________________ 107 © Festo Didactic GmbH & Co.1.9 6 Start up MPS stations __________________________________________ 74 Start up commissioning station __________________________________ 75 5.2 Reset process of MPS-stations _______________________________ 74 5.1 Settings ______________________________________________________ 88 7.1.4 Create a new order ____________________________________________ 103 7.10 Default mode _________________________________________________ 76 5.1.2 Reset process robot station _________________________________ 75 5.1 Requirements _____________________________________________ 74 5.4.3 Operation ____________________________________________________ 90 7.2 7.5 Reference guide to create a new order ________________________ 103 Workaround Error on Storage Station ____________________________ 105 Process description _______________________________________________ 107 8.1 Distributing Station ___________________________________________ 107 8.1 6.8 5.1 System information ____________________________________________ 79 6. • prolog-factory .1 Requirements _____________________________________________ 75 5.9.8.Contents 5.8.KG.9.1 8 Software requirements _____________________________________ 87 7.

KG.6.1 Standalone mode of Robot Station and Robotinos ______________ 136 8.7 Separating Station ____________________________________________ 130 8.4 Pick & Place Station ___________________________________________ 116 8.8.1 8.9 Standalone mode of Sorting Station _________________________ 134 Robot Station and Robotinos ___________________________________ 136 8.7.2 MES mode of Testing Station _______________________________ 112 8.2 MES mode of Distributing Station ___________________________ 108 Testing Station _______________________________________________ 110 8.3 Processing Station ____________________________________________ 114 8.1 8.4.8 Sorting Station _______________________________________________ 134 8.2.1 Standalone mode of Storing Station _________________________ 120 8.7.2.1 Standalone mode of Separating Station ______________________ 130 8.1 8.6.1 8.1.5.2 MES mode of Robot Station ________________________________ 140 8.1 Standalone mode of Testing Station _________________________ 110 8.Contents 8. • prolog-factory 9 .2 MES mode of Storing Station _______________________________ 124 8.3 MES mode of Robotino 1 ___________________________________ 146 © Festo Didactic GmbH & Co.2 MES mode of Separating Station ____________________________ 132 8.9.9.3.5 Standalone mode of Pick & Place Station _____________________ 116 Fluidic Muscle Press Station ____________________________________ 118 8.6 Standalone mode of Processing Station ______________________ 114 Standalone mode of Fluidic Muscle Press Station ______________ 118 Storing Station _______________________________________________ 120 8.2 8.9.

2.KG.3 Wiring ______________________________________________________ 159 11.1 Power supply ________________________________________________ 157 11.3.2 Controller ___________________________________________________ 158 11.Contents 8.2 Work pieces _____________________________________________ 153 10 Pneumatic _____________________________________________________ 155 10.2.4 9 Technology ______________________________________________________ 151 9. • prolog-factory .9.1 drawings ____________________________________________________ 151 9.1 11 Pneumatic supply _____________________________________________ 155 Electrical system ________________________________________________ 157 11.1 10 MES mode of Robotino 2 ___________________________________ 149 I/O-Components __________________________________________ 159 © Festo Didactic GmbH & Co.1 Pallet ___________________________________________________ 152 9.2 Modules in use _______________________________________________ 152 9.

and software for this model production.KG. The mobile robots receive their transport orders from the MES according to the warehouse management data. Complete operating instructions which explain the processes of the system are available for working with the system. This manual describes working with the prolog-factory system. With the help of graphics or pictures a simple communication should be obtain. After completion. various production technologies have been combined into one installation.2 2. where the customer orders are picked The Warehouse Area. Festo Didactic succeeded in using the most updated industrial hard. the comprehension of the process and the interaction of the respective components appear in clear presentation. The aim of the installation is the increase of competence. • prolog-factory 11 . The warehouse is served by mobile robots. The Commissioning Station consists of a 6 axis robot.1 Introduction General In the development of the system. to technical and social competence. Everything is explained and described for the operation of necessary events. the pallets (orders) are put to the warehouse input slide. The PRO-LOG Factory consists of 3 main areas: The Production Line. Each Station has its own controller to support a decentralized control structure. The customer orders are completed according the order data in this station. where the customer orders (pallets) are buffered until delivery The production line itself consists of 8 MPS Stations. from a simple setting of examples up to a complete production process. Additionally. where the products are produced The Commissioning Station. They move Empty pallets to the commissioning robot Completed orders from the warehouse input slide to the high-bay storage Deliveries from the storage to the warehouse output slides © Festo Didactic GmbH & Co. including all features. Station manuals are also available for the individual stations.

KG. • prolog-factory .Introduction 2.2 Customer system Overview prolog-factory system 12 Position Description Position Description 1 Triple stack magazine station 8 Sorting station 2 Testing station with color sensor 9 Robotino 2 3 Processing station 10 Robotino 1 4 Pick and place station 11 Log area 5 Fluid muscle station 12 Commissioning station 6 Storing station 13 Connecting conveyor 3 7 Separating station © Festo Didactic GmbH & Co.

KG. • prolog-factory 13 . Up to eight workpieces are stored in each of the magazine tubes of the stacking magazines. A double-acting cylinder pushes the workpieces out one at a time directly to the transfer point of the downstream station. © Festo Didactic GmbH & Co.Introduction 2.1 Triple stack magazine station Triple stack magazine station The triple stack magazine station separates workpieces from 3 magazines.2.

A retro-reflective sensor monitors whether the operating space is free before the work piece is measured for height. At the same time a color sensor is checking out the color of the work piece. An analogue sensor measures the height of the work piece.KG. • prolog-factory .2 Testing station with color sensor Testing station with color sensor The Testing station detects the various properties of the work pieces inserted into it. 14 © Festo Didactic GmbH & Co.Introduction 2.2. The parts are guided on the conveyor to the neighboring station. It differentiates work pieces with the aid of an laser distance sensor and a color sensor. Faulty work pieces are rejected via a slide.

the work piece is clamped by a solenoid actuator. On the rotary indexing table. the work pieces are tested and drilled in two parallel processes. work pieces are tested and processed on a rotary indexing table.KG. A solenoid probe with an inductive sensor checks that the work pieces are inserted in the correct position. This station only uses electrical drives.Introduction 2. © Festo Didactic GmbH & Co. • prolog-factory 15 . The table is positioned by a relay circuit. with the position of the table being detected by an inductive sensor.2.3 Processing station Processing station In the Processing station. Finished work pieces are passed on via the electrical sorting gate. During drilling. The rotary indexing table is driven by a DC motor.

2.4 Pick and place station Pick and place station The Pick and Place station is equipped with a two-axis Pick and Place module.KG. A light barrier detects the work piece at the end of the conveyor. This station can also be used to perform the following tasks: Rejection of work pieces (housing or basic body) on the slide Alternative feeding of work pieces (housing or basic body) from the slide 16 © Festo Didactic GmbH & Co. The work piece is transported to the pneumatic separator on the conveyor and detected by a second diffuse sensor. The Pick and Place module picks up a work piece insert from the slide and places it on the work piece housing. The complete work piece (housing and insert) is released by the separator and transported to the end of the conveyor.Introduction 2. • prolog-factory . Work piece housings placed on the conveyor are detected by an optical diffuse sensor.

• prolog-factory 17 . The pneumatic muscle performs the pressing operation. An optical diffuse sensor is attached to the arm of the actuator for sensing the work piece. © Festo Didactic GmbH & Co. The press-in speed and depth can be varied both manually – via throttle and pressure regulator – and electronically – via the proportional pressure regulator. The pressing pressure is monitored and displayed using the analogue pressure sensor. The finished work piece is then transported to the transfer position using the rotary/linear actuator.5 Fluid muscle station Fluid muscle station The Fluidic Muscle Press station presses work piece inserts into the housings.Introduction 2.2. The rotary/linear actuator (transfer device) moves the housing with the insert placed on it under the press.KG.

During placement into storage. The work piece is placed in the next free compartment in the corresponding storage level based on the color. The Storing station can be employed as the first station or the last station in an MPS® combination. the work pieces are transported from the shelf compartments to the downstream station. • prolog-factory . Upon removal from storage.6 Storing station Storing station The Storing station places work pieces in. The station is equipped with three storage levels. a work piece inserted in the Holder module is detected using the color sensor. and takes work pieces out of storage. with a level each for six red.KG. six silver and six black work pieces. The stroke movement is executed using an electrical linear axis with separate controller. 18 © Festo Didactic GmbH & Co.Introduction 2.2. The rotary movement is performed by an electrical servo drive with integrated controller. The work pieces are gripped using a pneumatic gripper. The linear movement is executed using a linear cylinder.

It separates them into two different material flow directions.Introduction 2. the black and silver are transported to the rear. transported to the end of conveyor).7 Separating station Separating station The Separating station differentiates work pieces based on their color and material with an inductive and an optical sensor. In default mode the red workpiece are transported to the end of conveyor. • prolog-factory 19 .2. The Separating station can be supplemented with MPS® downstream stations in two directions. if it is matching with the order (If not.KG. In MES mode the workpiece is transported to the rear. © Festo Didactic GmbH & Co. Fibre-optic through beam sensors with optical sensors monitor the material flow on the conveyors.

metal). Work pieces placed on the start of the conveyor are detected by a diffuse sensor.2. • prolog-factory . A retro-reflective sensor monitors the level of the slides.Introduction 2. 20 © Festo Didactic GmbH & Co. red.8 Sorting station Sorting station The Sorting station sorts work pieces onto three slides.KG. Sensors upstream of the stopper detect the work piece features (black. Sorting gates actuated by short-stroke cylinders via a deflector allow sorting of work pieces onto the appropriate slides.

The commissioned pallets are moved to the output slide for further use.KG. The complete handling of pallets and work pieces is done be the robot. • prolog-factory 21 .9 Commissioning station Commissioning station The commissioning station commissions work pieces from a conveyor on pallets.2. Empty pallets are moved from the input slide to the buffer positions on the station.Introduction 2. © Festo Didactic GmbH & Co.

The slides to the commissioning station are to supply the commissioning station with empty pallets and to take the equipped pallets from. A further slide for the input of empty pallets is available.2. The high bay racking is used to buffer up to 6 pallets. 2 robotinos are responsible for the handling of the pallets.KG.Introduction 2. There are 3 slides for the output of the pallets. Each of these slides is equipped with a RFID Sensor. • prolog-factory .10 Log area Log area The log area is a logistic field of 2x2m. 22 © Festo Didactic GmbH & Co.

• prolog-factory 23 .Introduction 2.KG. The task of the first robotino is to move the pallets from the output slide of the commissioning station to the high bay racking and to pick up the emtpy pallets from the input slide of the log area and move them to the input slide of the commissioning station. © Festo Didactic GmbH & Co. The task of the second robotino is to move the pallets from the high bay racking to the 3 outputs slides from the log area.2.11 Robotino 1&2 Robotino The 2 robotinos are equipped with a lifting system to lift and lay down the pallets from and to the slides.

from single use of modules to the complex and complete installation. This is an ideal training area for the professional practice of mechatronics. The robot’s programming can be started. Moving the robot and teaching the required positions are the first real operations with the robot.g.KG. 24 © Festo Didactic GmbH & Co. Perhaps even in combination with further systems. Small programs. electrical and pneumatic processes) are represented in a simple and clearly way. the modules can be interconnected and the programs can be adapted. as soon as the robot can be moved by the teach-box. as well as all of the technical ranges (mechanical. The following step could be the connection of all cables required for operation and the set-up of the robot. A complete production process can be simulated. • prolog-factory . which introduces the user how to deal with the teach-box. the robot. to enable methodical learning.3 Didactic structure The installation is structured. these learning steps can be transferred to the next module. For example.e. e.Introduction 2. Orders to further stations and from other controls can be installed in the programs. i. As soon as all of the modules have been processed individually. Once the learning process of this module has been concluded. it is possible to pick out a single module to start with the first steps. are expandable for the complex programs. which can be created by using the CIROS/Cosirop software. The robot’s radius of action requires integration into the location of the robot. concerning each one of the modules and the complete system. First the mechanical assembly is considered.

valves. each technology is considered first separately and then combined together to optimize the manufacturing processes. Training contents covering the following subjects can be taught: Mechanic: Adjusting of a handling system Assembly of singular station Using mechanical interfaces Electronic: Wiring and testing electrical components Reading and designing electrical circuit diagrams Getting familiar with electrical drives Working with electrical interfaces Robotic: Use of industrial robots Fundamentals of robot technology Robot programming Sensoric: Using limit switches and sensors Getting to know different types of sensors (inductive. capacitive. analogue) Pneumatic: Professional tubing of pneumatic components according to circuit diagrams Getting to know and using pneumatic components (different cylinders.KG. • prolog-factory 25 . optical.Introduction The installation permits to face students to the reality of manufacturing processes by allowing them to apply individual technologies already taught in the preliminary phases of engineering studies. Thus. grippers) Using vacuum technology © Festo Didactic GmbH & Co.

counting Maintenance and Troubleshooting: Locating and rectifying faults and malfunctions Optimizing automated systems Commissioning: Adjusting mechanical and electrical components Adjusting sensors and limit switches in automated systems Commissioning systems by means of a PLC 26 © Festo Didactic GmbH & Co. • prolog-factory .Introduction Ident system: Getting familiar with the Identification system Data processing via Ident and PLC PLC: Getting to know the structure and mode of operation of a PLC Programming a PLC in different PLC languages Interfacing a PLC to a Robot Controller and a visualization system Getting to know special function modules for positioning.KG.

2.4 Duty of the operating The operating authority undertakes to ensure that the system is used only by persons who: authority are familiar with the basic regulations regarding operational safety and accident prevention and who have received instructions in the handling of the system.Introduction 2. observe the basic regulations regarding operational safety and the prevention of accidents. all persons assigned to working on the system have a duty to: read the chapter on safety and the cautionary notes in this manual and. • prolog-factory 27 . © Festo Didactic GmbH & Co. Safety-conscious working of the persons should be regularly vetted. have read and understood the chapter on safety and the cautionary notes in this manual.5 Duty of trainees Prior to commencing work.KG.

commissioning. maintenance and operation. Festo Didactic herewith rules out any liability for damage or injury to trainees. These are available to the operating authority upon conclusion of the contract at the latest. operation. Furthermore this manual describes setup and possible uses of the singular stations. the training company and/or other third parties which may occur during the use/operation of the system other than purely in a training situation. Warranty and liability claims for persons or material damage are excluded if these can be traced back to one or several of the following causes:  Use of the system not in accordance with its intended purpose  Incorrect assembly. 28 © Festo Didactic GmbH & Co.6 Warranty and liability In principle all our „Terms and Conditions of Sale“ apply.7 Intended use This installation was developed and manufactured only for use in basic and further training in the fields of automation and communications. The use of the system for its intended purpose also includes: Following all advice in the manual and Carrying out inspection and maintenance work. except Festo Didactic has caused such injury or harm intentionally or by grossly negligence. unless such damage has been caused intentionally or due to gross negligence by Festo Didactic. maintenance and setting up of the system  Unlawful constructional modifications on the system  Inadequate monitoring of components subject to wear  Incorrectly carried out repairs  Catastrophes as a result of foreign bodies and vis major. It contains all information and data required for commissioning.Introduction 2. Festo Didactic accepts no liability for injury or harm to trainees. • prolog-factory . commissioning. The training company and/or the training staff must ensure that the trainees observe the safety precautions described in the accompanying manuals. 2.KG. storage. operation and maintenance of the system  Operation of the system using faulty safety equipment or incorrectly fitted or non operational safety or protective devices  Non observance of notes in the manual regarding transport. the training company and/or any third parties occurring when the installation is used for any purpose apart from training. assembly.

8 Important notes The basic requirement for safe use and trouble-free operation of the system is to observe the fundamental safety recommendations and regulations. Furthermore. The safety recommendations in particular must be observed by anyone working on the system. © Festo Didactic GmbH & Co.Introduction 2. the rules and regulations for the prevention of accidents applicable to the place of use must be observed. This manual contains important notes concerning the safe operation of the system.KG. • prolog-factory 29 .

Introduction 30 © Festo Didactic GmbH & Co. • prolog-factory .KG.

1.1 Dangers in handling the machine The installation has been constructed technologically up to date and in conformance with the recognized rules of safety engineering. Therefore. Safety endangering malfunctions cannot be tolerated during training and have to be removed immediately.KG. the installation has to be handled according to specified operational use in perfect technical condition only.1 General safety instructions Handling the system 3. The system is to be used only: for its intended purpose and in absolutely safe conditions. during operation it is possible that harm might be caused to the user or third parties or that the installation or other property might get damaged. Faults impairing safety must be rectified immediately! © Festo Didactic GmbH & Co.3 3. • prolog-factory 31 . Nevertheless.

Only trained experts in electric or electronic engineering are permitted to carry out work on the electric supply system. General safety regulations are to be observed: DIN 58126 and VDE 0100. 3. Access must be permitted only under supervision of a member of the training staff.KG. check the installation for externally visible damages and for the reliability of the safety devices. At least. Before circuit construction. circuit disassembly and circuit modification: switch off air pressure and power supply. • prolog-factory . The terminal boxes are to be kept closed at all times.3 Dangers due to electric current As soon as maintenance is completed. once all of the protection settings are completely functional. check the function reliability of the safety devices. Tools are to be used.1. Do not activate electric limit switches manually during fault search. before starting operation.1.General safety instructions 3. Do not grip into the installation while in operation. Only low voltage 24VDC is to be used.2 Safety precautions in standard operation Put the installation into operation only. 32 © Festo Didactic GmbH & Co.

See data sheets. caused by air pressure. Secure the compressed air and electricity supplies to prevent unintentional start-up. maintenance and repair work.1. in accordance with the specified intervals. 3. Interrupt air pressure supply immediately. inspection or repair work must be checked to ensure correct re-tightening. Exception: Fault finding.1. Caution! When the air pressure supply is activated. the machine must be deenergized. Do not exceed the permitted operating pressure. © Festo Didactic GmbH & Co.General safety instructions 3. Do not uncouple any tubes under air pressure supply. • prolog-factory 33 . All screw connections released during maintenance. cylinders may move in or out. de-pressurized and secured against unexpected restart.KG. 3.1. In this case.6 Organizational measures All existing safety devices must be checked at regular intervals.4 Dangers due to pneumatic energy Accidents might occur due to bouncing off tubes. During inspections.5 Maintenance – Servicing – Malfunction removal Carry out adjustments and inspections as instructed. keep on holding the end of the tube.

Each station has its own emergency stop.1 Notes on personnel Basically two situations have to be considered.3 34 Emergency stop system There is no superior emergency system.2.2.KG. Special care should be taken regarding safety aspects. Activities during training operations Activities outside training operations 3.General safety instructions 3. • prolog-factory . service and repair are to be carried out by only persons with appropriate technical qualifications. 3.2.3 Outside training operations Activities in the areas of maintenance.2 Training operations Trainees are permitted to work with the machine only under strict supervision of an experienced person or an instructor.2 Personnel 3. © Festo Didactic GmbH & Co. concerning matters on personnel. 3. Activities of trouble-shooting and fault correction are to be checked by the instructor.

This symbol indicates operational tips and especially useful directions. This symbol indicates an immediate threat to a person’s health or life.General safety instructions 3. This symbol emphasizes important information for correct machine handling. • prolog-factory 35 . which may even lead to life-threatening injuries. © Festo Didactic GmbH & Co. IMPORTANT Failure to pay attention to this symbol may result in damages to the machine or to its surroundings.1 Safety symbols In this manual the following danger designations and signs are being used. DANGER ! Failure to pay attention to this symbol may result in serious health damage.3.KG. i INFORMATION This symbol assists you to make optimal use of all of your machine’s functions.

KG. • prolog-factory .General safety instructions 36 © Festo Didactic GmbH & Co.

The carrier and Festo Didactic are to be notified immediately of any damage. Please check the stability of all of the profile connectors by means of an Allen key size 6.KG. The transport boxes are to be opened with care. Festo Didactic must be notified immediately of any discrepancies. as additional components. Installation of warning signs or barriers may be required. due to inevitable vibration. Sensors and similar small parts are very easily damaged in case of improper transport. Check the station for any possible damaged once unpacked. 4. such as computers may be contained in the delivery. The connectors may have come loose during transport. Check the station for any possible damaged once unpacked. to be accessible to the transport vehicle. When unpacking the station.2 Scope of delivery Check the scope of delivery against the delivery note and the order. The route of transport is to be cleared in advance. © Festo Didactic GmbH & Co. make sure that none of the station assemblies have been damaged. The weight amounts up to 500 kg. depending on the station.1. 4. Pay special attention to all overhanging components.1 Unpacking Carefully remove the padding material in the container box when unpacking the station. which are to be protected from falling out.4 Commissioning 4. The carrier and Festo Didactic are to be notified immediately of any damage.1 Transport Care is to be taken that the transport of the stations is to be executed only by a suitable transport vehicle. the station can be taken out to be transported to its destination by means of two fork-lifts or one fork-lift truck. • prolog-factory 37 . The stations are not to be picked up by or even under the mounted feet – increased risk of becoming trapped or contused. i Once the transport box has been opened and the possibly contained additional components removed.1.

KG. 38 © Festo Didactic GmbH & Co.2. In countries with an atmospheric humidity over 70% and temperatures above 25 degrees Celsius are the premises to provide an air-conditioning system for constant surroundings conditions. by means of a spiritlevel. The log area is the first station of whole system which is built up. if not done so previously. Allow sufficient distance between the installation and the wall of the room. large motors and contactors are to be checked for electromagnetic compatibility in advance and screened where necessary. To comply with the regulatory guidelines. The station is placed in its final position. sources of electrical interference such as welding plants. To ensure fault-free operation a load-bearing floor is required to avoid settling.2 Set up 4.e. • prolog-factory . Any dust originating from construction work has to be kept off the installation (by covering). For the set-up of the system follow the instructions below: At first the room has to be measured.1 General information The installation is to be set up in a frost-free room with maximum relative air humidity of 70%.Commissioning 4. The measures of all stations has to be marked roughly onto the floor space (i. The table from the log area should be at a height of 785 mm. with adhesive tape) to avoid shifting at a later stage. before it is balanced.

Commissioning For a more simple room planning the complete installation design is shown in the following. • prolog-factory 39 . Installation design prolog factory © Festo Didactic GmbH & Co.KG.

• prolog-factory .Commissioning Dimension drawing 40 © Festo Didactic GmbH & Co.KG.

3. (reducer 1/8 on 1/4 necessary). it is possible to change the coupling of the maintenance unit with a greater one. © Festo Didactic GmbH & Co. If an extension for the cable is necessary for the distribution strip. corresponding to the customer. once all of the stations are connected to their definite position.2 Electric commissioning The stations must be provided with electrical voltage now. If the available system is equipped with 7. enclosed to this also for the connection of other stations.3 Commissioning Commissioning of the system can ensue only.Commissioning 4. The voltage supply is a 24 V power supply unit. this can to be executed only by a trained expert.KG. individual protection (16A) of the installation is recommended. • prolog-factory 41 . If this has been carried out.9 mm nominal diameter. The delivered cables have a completely protected norm plug. this must be plugged into an electrical socket protected sufficiently. The power supply (24 VDC) of the sensoric and the actuators of the station is provided in each case by means of a 2-pin cable. The electrical socket must be protected. To avoid problems during the operational process. The stations are provided with a power supply unit which is provided with a voltage of 110/230 V. 4.3. In most cases the maintenance unit is on the profile plate of the station. Distribution strips are. At the beginning the stations have to be attached to the pneumatic system of the room. contained in the control cabinet or somewhere in the station. The coupling has a 5 mm nominal diameter.1 Pneumatic commissioning The mechanical construction must be finished. 4. the stations can be provided with 600 kPA/6 bar and the pneumatic commissioning is realized.

The control levels are: Factory level: Order Entry Plant level: SCADA Device level: PLC.3 Connecting communication cables The PRO-LOG Factory covers all state of the art industrial communication levels and control technologies.KG.Commissioning 4. • prolog-factory .3. RC The communication systems are:  Ethernet (LAN/WLAN) for communication between PLC and PC (see also following graphic)  RFID for communication between external I/O parts and PLC (see also following graphic)  Profibus for communication between Siemens PLC and Turck IO extension 42 © Festo Didactic GmbH & Co.

All connections are pluggable. the exception is the cable from the Drive unit. • prolog-factory 43 . the cable is fixed in the drive unit and not pluggable.Commissioning The communication inside the system takes place via Ethernet and Profibus DP. Ethernet communication cables © Festo Didactic GmbH & Co.KG.

6 11 Separating station 192.168.168.101 15 Robotino 2 192.168.168.Commissioning 44 Position Station Ethernet address 1 MES PC 192.KG.2 7 Processing station 192.1 4 LAN-switch 5 WLan router 192.10.10.10.168.168.168.5 10 Storing station 192.10.10.10.10.101.20 14 Robotino 1 192.4 9 Fluid muscle station 192. • prolog-factory .168.50 2 WinCC 192.168.10.168.2 6 Testing station with color sensor 192.168.8 13 Commissioning station 192.10.10.10.168.168.168.10.51 3 Triple stack magazine station 192.3 8 Pick and place station 192.7 12 Sorting station 192.102 © Festo Didactic GmbH & Co.10.

Commissioning Profibus communication cables Position Station Profibus DP address 1 Turk CPU commissioning station DP # 3 2 Drive unit roboter DP # 10 3 PLC commissioning station DP # 2 4 Turk connecting unit log area DP # 5 © Festo Didactic GmbH & Co. • prolog-factory 45 .KG.

KG.Commissioning RFID communication cables 46 Position Station name 1 RFID sensor robot 1C1 2 RFID Card 1 for RFID sensor robot and slide 1 1K2 3 RFID Card 2 for RFID sensor slide 2 and slide 3 1K3 4 RFID sensor slide 1 1C2 5 RFID sensor slide 2 1C3 6 RFID sensor slide 3 1C4 © Festo Didactic GmbH & Co. • prolog-factory .

1.1 General operation notes The stations require some rules of operation which should be observed.1.KG. • prolog-factory 47 . faults in the processes are possible. 5. 5. Water has to be kept away from the plant. © Festo Didactic GmbH & Co. as well as operating with the system. It is recommended to observe the following rules strictly. Dangers for the physical health also cannot be excluded. If they are not complied. 5.1 Behaviour rules During the operation of the stations it is forbidden to grip in by hand. With larger audience a mechanical protection of the stations is necessary.2 Operation rules The stations only may be used by introduced persons. Removing any cable under tension is forbidden. No work piece carriers may be taken by the system. The operation has to be carried out according to the operating instructions. A pushing the different switches/push buttons of all control units unchecked has to be stopped.5 Operation This chapter describes the necessary control units for starting and stopping the system.

there the orders are deleted. Robotino 1 takes the pallet from the slide and moves it to the high bay racking for temporary storage.KG. it is necessary to put out the pallets by hand. It is possible to equip the pallet with 1-4 different work pieces. otherwise the work piece is sorted out on the slide. The separating station gets the work pieces from the Storing station and the testing station gets the work pieces from the distribution station. The requirement therefore is that the slides are not occupied – in case the slides are occupied. If the pallet is equipped. the robot takes the pallet and places it down at the outlay slide from the station. • prolog-factory . 48 © Festo Didactic GmbH & Co. The commissioning station requests the necessary work pieces at the separating and testing station. From there robotino 2 moves the pallet to the respective outlay slide (Slide 1-3) of the system.Operation 5.2 Process description Orders are entered and started in MES software. The RFID sensors announce this in MES software. There the work piece is checked for height and the color – the color must fit to the respective order. The commissioning station has to equip a pallet like defined in the order.

According to the customer orders. The pallets are stored in a high bay storage. There are buffers and magazines for the raw materials. The mobile robots are equipped with a fork on a telescope arm and work as a fork lift to reach the upper positions of the high-bay racking. and a storage for the single products.KG.1 Material flow The processes and the material flow in PRO-LOG Factory is an image of a real production and distributing enterprise. Position Material flow Station 1 Work pieces from MPS-System MPS Stations 2 Equipped pallets to high bay storage Robotino 1 3 Equipped pallets to outlay slides 1-3 Robotino 2 4 Empty pallets Robotino 1 5 Sort out work pieces Sorting Station © Festo Didactic GmbH & Co. • prolog-factory 49 .2. the products are transported JIS (just in sequence) to the commissioning robot.Operation 5.

KG.Operation Position numbers Robotino / orientation of pallets Position Position number robotino 1 High bay rack position 1 2 High bay rack position 2 3 High bay rack position 3 4 High bay rack position 4 5 High bay rack position 5 6 High bay rack position 6 7 Commissioning station output slide position 7 8 Commissioning station input slide position 8 9 Log area input slide position 9 / Init position robotino 1 10 Log area output slide 3 position 10 11 Log area output slide 2 position 11 12 Log area output slide 1 position 12 13 Init position robotino 2 The black numbers are the work piece positions on the pallets. There you can see the orientation of the pallet. 50 © Festo Didactic GmbH & Co. • prolog-factory .

KG.Operation 5.3 Robotino information and operation Operation display robotino Position Function Position Function 1 Display line 1 6 Power button 2 Display line 2 7 Move upwards in menu 3 Display line 3 8 Enter Button 4 Display line 4 9 Move downwards in menu 5 Powers supply light 10 Move back on layer in menu © Festo Didactic GmbH & Co. • prolog-factory 51 .

3. 52 © Festo Didactic GmbH & Co. press the Return button to bring back the panel to operation.Operation 5. If the charge of the accumulator is not more than 50% it is possible that the robotino doesn’t work exactly – in this case or in case of a crash press any button to stop the robotino. the operation of robotino 2 is equal. the display is going to stand by mode. • prolog-factory . The external AP switch has following modes Left position = AP mode right position = Client mode To guarantee constant 5V it is necessary to connect the gyroscope to the USB-Hub at the robotino.1 General The example is written for robotino 1.KG. If there is no operation at the panel during start up the robotino.

• prolog-factory 53 .KG.Operation The memory card with the system software has to be available in the slot of the robotino. CF Card slot © Festo Didactic GmbH & Co.

KG. The accumulator of the robotino has to be loaded more than 50%.2 Start up To start up the robotino.rvw2 (for robotino2) if the program is not available see chapter Download a program to robotino Be sure that the robotino is at the right starting position (See following picture – the lift has to stand like shown in the graphic – arrow announce direction) pay attention for the mark on the table. Press the ENTER button and the system is coming to the main menu. 3. See (Line 4 in display) If not happened disconnect the charge cable from the robotino.x_R2. follow the instructions: 1. 5.3. 4. the IP address and the accumulator charge condition. Load up the accumulators with help of the recharger cable for 2-3 hours.x_R1. 7. The power supply light is starting to lighten and the digits of the display are active. 6.Operation 5. Choose program ->Prolog_Vx. The controller is booting – wait till the display shows the robotinos name. Press the Arrow down Button to choose the line with the programs and press the ENTER button. 2. Pos Function Start 1 position robotino 1 Start 2 54 position robotino 2 © Festo Didactic GmbH & Co.rvw1 (for robotino 1) ->Prolog_Vx. • prolog-factory . Press Power button for more than 2 seconds.

– The power supply light expires.Operation 8. 9. © Festo Didactic GmbH & Co.3. • prolog-factory 55 . After reference move the robot is in start position and is waiting for orders.KG. Press ENTER button Robotino makes the reference move.3 Switch off the robotino To switch off the robotino press the power button for more than 3 sec. 5.

• prolog-factory .1_R1  ProLog_V1.Operation 5. In the display-screen  If the light is not active. you have to go in the menu “programs”  Here. you will see one of the both programs :  ProLog_V1.4 Program start For both robotinos: 1.1_R2  R1 is the robot with the start-position 9.KG. press enter  Press enter.  Position the robotino left-handed to the right position  Start the program with enter 56 © Festo Didactic GmbH & Co.  R2 is the robot with the start-position 13. you will be in the main menu  With the buttons.

• prolog-factory 57 .101 Startposition 13. Make sure to download the right program:   Robotino 1: Robotino 2: Startposition 9.10.168.168.102 Open the following program for robotino 1 Or for robotino 2 © Festo Didactic GmbH & Co. IP address 192. IP address 192.10.KG.6 Program Upload robotino The steps to upload the robotino’s program is the same for both robotinos.Operation 5.

Operation In RobotinoView 2 select the tab Main program Check the Robotino variable in the right column and set it accordingly: 58 Robotino 1 -> Value 101 Robotino 2 -> Value 102 © Festo Didactic GmbH & Co.KG. • prolog-factory .

The ports are different for the two robotinos: © Festo Didactic GmbH & Co.Operation Click on any sub program to get a list of directories on the right side of the program window Double click on UPD connection PLC control. The IP address should be the same as the main plc.KG. This opens a new window with the UDP connection settings. • prolog-factory 59 .

Operation Enter port 9180 for robotino 1: 60 Enter port 9181 for robotino 2: © Festo Didactic GmbH & Co. • prolog-factory .KG.

Operation Close the UPD connection control window and click on Upload project in the menu robotino © Festo Didactic GmbH & Co.KG. • prolog-factory 61 .

• prolog-factory .KG. The IP address of the Robotino is entered in both IP address fields. 62 © Festo Didactic GmbH & Co.Operation The FTP client within RobotinoView opens and connects to Robotino.

KG. Open the programs directory with a double click. • prolog-factory 63 .Operation If successfully connected. the Robotino directories are displayed. © Festo Didactic GmbH & Co.

Operation Click on Upload current project to upload the opened program The program is stored on the Robotino and can be started.KG. • prolog-factory . 64 © Festo Didactic GmbH & Co.

pos_target_y. LeaveDock Leave the docking-position. to posN_x.5 Robotino-Pro-Log Subprograms Name Description Init Initialize several global variables for OPC and update the value of OPC-job_running via OPC. FindStop Search the black band before the docking-position. ( only with inductive sensors) InitOdo Save the orientation. CopyJob1 Save the order of the PLC. Drive Drive to the Target-position defined with the global variables pos_target_x. SetOdoN Initialize the Odometry in saving the global Variable posN_x.KG. SetPosN Set the global Variable pos_target_x. When the fork is down. and pos_target_phi.Operation 5. when the Line is found. pos_target_y. and pos_target_phi. posN_y and posN_phi. posN_y and posN_phi. (with the inductive sensor in the middle of the Robotino and with the odometry) back Initialize several global variables for UDP and update the value of udp-job_running via UDP. • prolog-factory 65 . InitFork Initialize the fork. FindLine Search the metal-line and set the global variable lineFound to true. when the Line is found. © Festo Didactic GmbH & Co. set the global variable fork_isDown to true. Fork FindLine-Odo Search the metal-line and set the global variable lineFound to true. CopyJob Update the status of robotino via UDP SetForkN Set the global Variable fork_targetPosition to fork_posN_1 or Fork_posN_2. Positioning The fork drives to the position defined with the global variable fork_targetPosition.

KG. • prolog-factory . you can see that in the next schema: 66 © Festo Didactic GmbH & Co.Operation The Main Programm has several Parts.

4. Find the black band. (N=number of the source) If the Robotino is not already in the source-position then its drives to this position:  The Robotino leaves the dock. 7. • prolog-factory 67 .  Save the origin of the fork. Initialize the fork. (only with inductive sensors) Save the orientation.5.  The fork drives to the position fork_posN_1. The Robotino leaves the dock. 3.Operation 5. the Robotino drives to the target-position and do the following sequence:  Initialize the fork. (N=number of the source)  The Robotino finds the metallic line. The fork drives to the position fork_posN_2. (with inductive sensor and odometry)  The Robotino finds the black band.1 Explanations Initialization        5.KG. 8. © Festo Didactic GmbH & Co. That means the Robotino takes the palette in the source. 2. 5. Find the metallic line. Sequence to collect one Palette Wait for a job and save this job.5. (fork is down) Save the target position. If the Robotino is already in the source-position:  The fork drives to the position fork_posN_1. Wait the connection. Save the right parameters: save the target-position for the Robotino and the fork. Save the right parameters: save the target-position for the Robotino and the fork. 6. Save the coordinate of the start-position. (with optical sensor) Save the right parameters: save the right coordinates in the Odometry and save the next target-position for the fork.  In the same time.2 1.

68 © Festo Didactic GmbH & Co.  In the same time. If the Robotino is in the storage warehouse (position-number between 1 and 6) then the Robotino must drive to the start-position:  The Robotino leaves the dock.KG. (with optical sensor) 10. 13.  The fork drives to the position fork_posN_2. That means the Robotino gives the palette in the sink. (with inductive sensor and odometry)  The Robotino finds the black band. The fork drives to the position fork_posN_1. (N=Number of the sink)  The Robotino finds the metallic line.  Save the coordinate of the start-position.Operation 9.  Save the origin of the fork. the Robotino drives to the target-position and initialize the fork. Save the right parameters: save the right coordinates in the Odometry and save the next target-position for the fork. If the Robotino is not in the storage warehouse (position-number between 1 and 6) then the sequence is finished.  The Robotino finds the metallic line (with inductive sensor and odometry).  The Robotino finds the black band (with optical sensor). The Robotino drives to the sink-position:  In the same time. 11. the Robotino drives to the target-position and do the following sequence:  Initialize the fork.  Save the right parameters: save the target-position for the Robotino. 12. • prolog-factory .

• prolog-factory 69 . posX_phi © Festo Didactic GmbH & Co. when the dock is left.5. fork_posN_1 Position of the fork in the position N. gesamt Intermediate variable in the calculation of the PI-controller in the subprogram FindStop. fork_targetPosition The fork´s target-position. lineFound True. posX_y When the Robotino is docked. job_sink Sink-number of the next order transmitted via UDP to Robotino View. when the fork is on the fork-targetPosition. posX_1_phi posX_x Coordinate of the position X in the table-coordinates´ system.3 Global Variables Name Description Batterie Value of the Batteries in Volt. udp_job_running True. Fork_posN_2 is always upside of fork_posN_1.KG. when the Robotino works about an order. CurrentPos Number of the current position (between 1 and 13). False. Robotino The Robotino´s number 101: starting position is pos09_1 102: starting position is pos13_1 dockLeft True.Operation 5. posX_1_x Coordinate of the position X_1 in the table-coordinates´ system. when the Robotino has found the metallic line and is aligned with this line. when the Robotino is waiting an order. the odometry save the coordinate of the position X. posX_1_y The position X_1 precedes the position X: the Robotino go first in the position X_1 and search the metal-line from this position. fork_posReached True. job_source Source-number of the next order transmitted via UDP to Robotino View. Fork_posN_2 Position of the fork in the position N.

stopFound This variable is in the subprogram FindStop. True. pos_target_y pos_target_phi rearSensorHitLine This variable is in the subprogram FindLine. if the inductive sensor has already once detected the metal-line or not.KG. pos_target_x Coordinates of the target-position in the table-coordinates´ system. and pos_target_phi of subprogram Drive. 70 © Festo Didactic GmbH & Co. job_source Source-number of the next order transmitted via UDP to Robotino View. when the Robotino works about an order.6 Data Exchange Variables Name Description CurrentPos Number of the current position (between 1 and 13).Operation Name Description pos_reached True. job_sink Sink-number of the next order transmitted via UDP to Robotino View. X Coordinate of the Robotino (given by the odometrie) in the table-coordinates´ system. job_running True. It saves. 5. when the Robotino is on the docking-position. pos_target_y. when the Robotino is waiting an order. when the optic sensor has detected the black band. Y Phi These variables are present in the both programs. That mean. • prolog-factory . when the Robotino is on the position pos_target_x. False.

7.1 General Position Function Positi on Function 1 High bay rack 6 Robotino 2 2 Robotino 1 7 Output slide 1 (order 1) 3 Slide from commissioning station to log area 8 Output slide 2 (order 2) 4 Slide from Log area to commissioning station 9 Output slide 3 (order3) 5 Turk controller board 10 Input slide 1 (empty pallets) There is no operation system for the log area. The control for the log area is done from the controller on the turk board. © Festo Didactic GmbH & Co.KG. The lamps at the slides announce that a order is ready and the pallet is on the slide. • prolog-factory 71 . The board is supplied with 24 V from a extern power supply unit.7 Log area information and operation 5.Operation 5. be sure that the power supply unit is switched on.

Operation The silver help lines on the table are for the Robotino. a optical sensor recognize the marker. 72 Position Function 1 Silver help line (aluminum tape) 2 The robotino orientates at the right edge of the help line 3 Marker to stop the robotino in the right position 4 Direction of robotino to handing over a pallet to a slide © Festo Didactic GmbH & Co. • prolog-factory . with a inductive sensor the Robotino follows the right edge of the line. The black markers are the stopping point for the Robotino. The help lines are available at the slides and at the high bay rack.KG.

KG.2 Start up log area Remove all parts from the outlay slides Remove all parts from high bay racking Fill up the Input slide with empty pallets © Festo Didactic GmbH & Co.Operation High bay rack Position Function 1 High bay rack position 1 2 High bay rack position 2 3 High bay rack position 3 4 High bay rack position 4 5 High bay rack position 5 6 High bay rack position 6 5. • prolog-factory 73 .7.

1 Requirements The reset process is the same for each MPS station.8 Start up MPS stations The operation of the stations is described in the stations manual – a short cut for operation to start up the system should be helpful.2 Fill up all magazines Clear all working positions Reset process of MPS-stations The MPS-stations can be started with the reset process.Operation 5.8. The reset process is also to be executed after STOP. 1. 5.8. 5. Execute the reset process at each station. 2. All stations have the same procedure. 74 © Festo Didactic GmbH & Co.KG. as following. • prolog-factory .or EMERGENCYSTOP activation.

3.1 Requirements Execute the reset process at the robot station. 5. The reset process is also to be executed after STOP. the high bay rack at the log area and the pallet reception at commissioning station.2 Reset process robot station © Festo Didactic GmbH & Co. Clear all working positions.or EMERGENCY-STOP activation. • prolog-factory 75 . 2.9. slides. 1.KG.9 Start up commissioning station The operation of the station is described in the stations manual – a short cut for operation to start up the system should be helpful. Switch on power and air supply Key switch on Drive Unit to Auto/EXT Switch Teach Box to disable Switch on Drive Unit from robot 5.Operation 5.9.

Operation

5.10

Default mode

Default mode MPS

76

The default mode is helpful to check the complete system. If the default mode works
without an error, all sensors and actors work faultless. In default mode all stations
starting automatically if the START button at the stations are pressed and all
stations are started without error.
1.
2.
3.
4.

Turn Key switch at all stations to default mode
Fill up all magazines at MPS stations
Start all stations with START button
If the start button at the triple stack magazine is pressed, the station is starting
to work. If the following station has now congestion jam, the first workpiece is
separated and transported to the next station. The sequence is starting with a
red workpiece, then a black, then silver and again a red workpiece etc.
5. The testing station checks the height from the workpiece. If the height is ok., the
workpiece has the right orientation and is transported to the next station. If the
height is not ok. the workpiece is sorted out on the slide
6. The processing station is processing the workpiece
7. The pick and place station implements an instrument into the workpiece
8. The Fluid muscle station is pressing the instrument into the workpiece
9. The storage station moves the red workpieces into the top row, the black
workpieces into the middle and the silver workpieces into the lower row. If the
following station is not occupied a workpiece is released from the storage. The
station takes the color with the most workpieces in stock
10. The sorting station is sorting out the red workpieces to the first slide. The black
and silver workpieces are transported to the commission station

© Festo Didactic GmbH & Co.KG. • prolog-factory

Operation

Default mode
commissioning

1.
2.
3.
4.
5.
6.
7.
8.
9.

10.

11.
12.
13.
14.

Turn Key switch to default mode
Place empty pallet to input slide at log area
Start commissioning station with START button
The robotino 1 takes the empty pallet from the input slide at log area (robotino
pos. 9) and moves to input slide of the commissioning station (robotino pos. 8)
The robot takes the pallet and moves to pallet reception position 1
If a workpiece is available from MPS line, the robot takes the workpiece from the
conveyor. The workpiece is transported to first position on the empty pallet.
If there is another workpiece, this is transported to second position on the
empty pallet. etc.
When the pallet is fully equipped, the robot takes to pallet to output slide of the
commissioning station
Robotino 1 is picking up the pallet from commissioning station and moves to the
high bay rack at the log area. There the pallet is stored to shelf 1 of the high bay
rack
Robotino 2 is picking up the pallet from shelf 1 at the high bay rack and moves
to output slide 1 from log area. There the pallet is made available for hand out
of the system.
This cycle is continued till all positions are tested once or the default mode is
stopped.
In the following the empty pallets from input slide at log area coming to pallet
reception 2 then 3 and 4.
If the first pallet is completely equipped, the workpieces coming to the pallets 2
then 3 and then to pallet 4.
The equipped pallets are coming to high bay rack shelf 2. From there to output
slide 2, from shelf 3 to slide 3 from shelf 4 to slide 1 etc.

© Festo Didactic GmbH & Co.KG. • prolog-factory

77

Operation

5.11

MES Mode

The MES mode is for automatic mode of the complete system. Operation and order
handling is done by the MES Software.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

78

Turn Key switch at all stations to MES mode (vertical – Auto)
Fill up magazine at distributing stations (MPS)
Prepare storage (MPS) equal the settings in MES
Remove all workpieces from storage
Remove all workpieces from working positions
Remove all workpieces from conveyor positions
Remove all workpieces from buffer at Log Area
Place empty pallet to input slide at log area
Start all stations with START button
Operation is done by MES Software (See chapter process description)
Announcement is done in WinCC

© Festo Didactic GmbH & Co.KG. • prolog-factory

6 6. Control And Data Acquisition) like WinCC.0 with SP1 with WinCC-Application Notice: Please make sure that all software and hardware has been installed in this order! © Festo Didactic GmbH & Co.KG.1. For data exchange between SCADA system WinCC and the PLCs an Ethernet network is used.1 Start-up WINCC Before activating WinCC you have to make sure all programs have been downloaded to each PLC and all system cable connections are made: DC24V power supply 6bar system pressure I/O communication cables according to operation manual Ethernet cables connecting each PLC and computer Ethernet cables are connected with the Ethernet switch Ethernet switch is switched on Profibus cables connecting PLC commissioning with Turk board System requirements: Windows XP with SP2/Vista. single MPS-stations can be removed or relocated. English or German Version with Internet Explorer V6.0 Ethernet-card installed to the computer WinCC V7. It is possible to configure the facility. WinCC can conform to the real system. 6. • prolog-factory 79 .1 WINCC System information The system is extended with a communication layer for using a SCADA system (Supervision. for this system it is called "Level 2". If this is done.

KG.2 Use Runtime Application Start screen with the overview of the system Buttons and functions overview 80 Position Function 1 Choose control panel of station 2 Announcement of chosen station 3 Announcement / operation of chosen control panel 4 Announcement in/outputs of chosen station (example with distribution station) 5 Announcement in/outputs of chosen station (example with testing station) 6 Announcement and choice of station at this position 7 Button to show details of the chosen station 8 Number and status of robotino.WINCC 6. green = ready / yellow = busy 9 Button to show I/O´s of the different stations / Screen change to I/O screen 10 Button to show the main view / Screen change to overview screen 11 Button to announce alarm window 12 Button to announce “shut down WinCC” © Festo Didactic GmbH & Co. • prolog-factory .

KG. it is also possible to see robotino information 7 Announcement and operation with the chosen control panel 8 Area for control of all stations 9 Button to show I/O´s of the different stations / Screen change to I/O screen 10 Button to show the main view / Screen change to overview screen 11 Button to the alarm screen 12 Button to shut down WinCC © Festo Didactic GmbH & Co.WINCC I/O screen. each field can be adjusted from the customer 5 If a station has a lot I/O´s. it is possible to switch to a second side to see the other I/O´s 6 Choose control panel from station / possible at all fields in control area. Buttons and functions I/O´s Position Function 1 Choose I/O´s announcement of station / possible at all fields in I/O area 2 Announcement of chosen station 3 Announcement in/outputs of chosen station (example with distribution station) 4 Area for I/O´s of all stations. • prolog-factory 81 .

KG. station is still working. quit error and push START button  ERROR_L2 / warning.WINCC Alarm in I/O´s window Position Function 1 Announcement of alarm at this station 2 Announcement of alarm somewhere in the system 3 Button to change to alarm window Alarm class description  ERROR_L0 / fatal error. station doesn’t work anymore. solve problem. quit Error and reference move necessary  ERROR_L1 / still working and stops at the cycle end. • prolog-factory . if necessary quit error 82 © Festo Didactic GmbH & Co.

WINCC Alarm window warning Position Function 1 Detailed alarm announcement / background grey for warning 2 Acknowledge and delete all alarms 3 Cancel alarm window without acknowledge the alarm © Festo Didactic GmbH & Co.KG. • prolog-factory 83 .

• prolog-factory .KG.WINCC Alarm window / error 84 Position Function 1 Detailed alarm announcement / background red for error 2 Acknowledge and delete all alarms 3 Cancel alarm window without acknowledge the alarm © Festo Didactic GmbH & Co.

Deactivate WinCC runtime and change to windows / WinCC is still active .WINCC Shut down menu Position Function 1 Choose function .Shutdown computer 2 Acknowledge function from shut down menu 3 Cancel shut down menu and change back to WinCC runtime © Festo Didactic GmbH & Co. • prolog-factory 85 .Close project and shutdown WinCC to change to windows .KG.Restart computer .

WINCC Configuration window 86 Position Function 1 Fault is announced (only in flash animation) / marked with the red frame 2 Description of fault 3 Confirm fault © Festo Didactic GmbH & Co.KG. • prolog-factory .

1.0 has to be installed MES Pos. If the option MES is selected at the control panel.Net framework V4. 7.KG.7 MES Software The Manufacturing Execution System software is responsible for the order management. • prolog-factory 87 . Description 1 Start the software with double click on the icon on desktop At the first start the window from the firewall has to be confirmed. all orders are executed from this software.1 Software requirements  Windows 7 with newest service pack  Microsoft. © Festo Didactic GmbH & Co.

Settings in common options Here you can adjust the common system. • prolog-factory . you can choose between common and communication.KG. If you choose the options. it is possible to        88 Delete all orders during start up Delete all buffers during start up Delete all finished orders during start up Set communication to active during start up Create Logfile edit time to refresh the overview Edit the order standard © Festo Didactic GmbH & Co.MES-Software 7.2 Settings At the flag “TOOLS” it is possible to reload the system or to edit the options.

it is possible to  Edit the port  Edit the quantity of clients It is recommended that the user doesn’t change something in these options. © Festo Didactic GmbH & Co. the program files have to be adjusted to the new settings. otherwise.KG. • prolog-factory 89 .MES-Software Settings in communication options Here you can adjust the communication.

Description Pos.3 Operation Start screen MES software The left side of the window is the order view and the right side is the main view. Pos. the main view is announced in real time. black or silver 90 10 Announcement of actual order in new window (See screen commissioning order) © Festo Didactic GmbH & Co.KG. Description 1 Change mode (see following screens) 6 Button to delete all orders 2 Change order announcement between list and 7 Button to disable all orders 8 Announcement of actual order 9 Announcement of actual order / with click in tree 3 Announcement of order to produce a cylinder Background white = order not started Background yellow = order started Background blue = order ready Background red = error 4 Announcement of order to produce a pallet field.MES-Software 7. • prolog-factory . a new window is opened 5 Announcement of workpiece in suborder Cylinder in red.

Description 11 Announcement of actual order in new window 16 Announcement of actual order in new window.MES-Software Pos. the position is marked green © Festo Didactic GmbH & Co. Description Pos.KG. (See screen commissioning order) 12 Announcement of actual order in new window it is possible to delete orders in the window 17 (See screen commissioning order) 13 Announcement of actual order in new window green = online / red =offline 18 (See screen commissioning order) 14 Announcement of actual order in new window (See screen commissioning order) 15 Announcement of status guilty for all stations New window with right click/See screen inventory 19 Announcement of actual order in new window (See screen commissioning order) If a pallet is available at a penholder position. • prolog-factory 91 .

MES-Software Overview – orders shown as tree Overview – orders shown as list 92 © Festo Didactic GmbH & Co. • prolog-factory .KG.

MES-Software Pos. (a reference guide to create a new order) © Festo Didactic GmbH & Co. Description 1 Change mode (see following screens) 8 Announcement of actual order / cylinder or pallet are possible If the order is a commissioning order it is possible to choose the order. • prolog-factory 93 .KG. Description Pos. to define the output slide and to edit each position 2 Announcement of not enabled orders – with 9 The single positions from the order are right click on order it is possible to enable or announced here. It is possible to choose and delete the chosen order edit each single position 3 Delete selected order 10 Delete selected position 4 Add new order 11 Cancel all edits 5 Enable all orders 12 Save all edits 6 Delete all orders 13 Add new position 7 Announcement of actual order – it is possible to edit the start date and the customer See also chapter create a New Order.

MES-Software Overview – orders shown for commissioning a palette Overview – orders shown to produce a cylinder 94 © Festo Didactic GmbH & Co. • prolog-factory .KG.

MES-Software Analysing orders Announcement of all produced orders. • prolog-factory 95 .KG. In the top area some choices can be done. © Festo Didactic GmbH & Co. Analysing parts Announcement of all produced parts.

MES-Software

Configuration – resources

96

Pos.

Description

1

Change mode (see following screens)

2

Choose configuration area

3

Announcement of resources / chosen resource is blue

4

Announcement of functions from the chosen resource

5

Announcement of parameters

6

Picture of resource

© Festo Didactic GmbH & Co.KG. • prolog-factory

MES-Software

Configuration – production orders

Pos.

Description

1

Change mode (see following screens)

2

Choose configuration area

3

Announcement of order / chosen order is blue

4

Select order types:
production (cylinder)
commissioning (feed a pallet)
templates (suborders)

5

Announcement of tasks of the chosen order

6

Announcement of parameters of the chosen task

© Festo Didactic GmbH & Co.KG. • prolog-factory

97

MES-Software

Configuration – buffers

Pos.

Description

1

Change mode (see following screens)

2

Choose configuration area

3

Announcement of storage / each line is one shelf, the content is announced or editable, / the blue line is
the active shelf

98

4

Save actual content

5

Choose resource of buffer

6

Choose buffer

7

Choose workpiece in shelf (red, black silver cylinder or pallet)

© Festo Didactic GmbH & Co.KG. • prolog-factory

it is not possible to delete the customer 6 Announcement and insert field for customer data’s / the customer number is only editable when a new customer is created 7 Cancel the new customer data’s 8 Save new customer data’s © Festo Didactic GmbH & Co.KG. Description 1 Change mode (see following screens) 2 Choose configuration area 3 Announcement / choice of customers 4 Create new customer 5 Delete chosen customer / If an order of the chosen customer is active.MES-Software Configuration – customer data Pos. • prolog-factory 99 .

the chosen order is blue marked / all active orders get marked in the last column of the table 4 100 Save orders © Festo Didactic GmbH & Co.KG. Description 1 Change mode (see following screens) 2 Choose configuration area 3 Announcement and edit of generated orders. • prolog-factory .MES-Software Configuration – generated orders Pos.

black or silver workpiece is possible 2 Choose sort of workpiece to edit workpiece in shelf 3 Cancel edits in inventory 6 Save edits in inventory © Festo Didactic GmbH & Co.MES-Software Inventory Pos.KG. Description 1 Announcement of shelf / red. • prolog-factory 101 .

MES-Software Show commissioning order Only announcement of commissioning order. • prolog-factory . 102 © Festo Didactic GmbH & Co.KG.

A new order. first set on commissioning. Click the Button ‘Add Orders’ 3.4 Create a new order 7. will be created 4.MES-Software 7. 5.1 Reference guide to create a new order 1. Choose ‘New Orders’ 2.KG. • prolog-factory 103 .4. Set a start date and time Set a customer that is configured in the database © Festo Didactic GmbH & Co.

On a commissioning order a delay time and a output slide can chosen On a commissioning order also the parts must be chosen Positions can added or deleted with the Buttons 10. Press ‘Ok’ when finished 11. 9.MES-Software 6. deleted or edited 13. The Orders that are not enabled are listed in the TreeView 12. This Order can enabled. If the Order is enabled it is Deleted from the New Orders and you can find it in the Overview 104 © Festo Didactic GmbH & Co. Change the type of the order 7.KG. • prolog-factory . 8.

Start Storage Station in Automatic Mode (MES) © Festo Didactic GmbH & Co.KG. Reset Storage Station 2.MES-Software 7. A part was not gripped  The position of the order is started and BUSY Workaround: 1. • prolog-factory 105 . Check the Storage content in the MES Software (ProductionControler) and correct the content 3. A part is lost on the way to the Separating Station 2. Rightclick on the Position with the wrong state (picture) And click reset position This position will be started again with first workorder 4.5 Workaround Error on Situation: Storage Station  Storage Station is on an Error 1.

• prolog-factory .MES-Software 106 © Festo Didactic GmbH & Co.KG.

it automatically jumps to the next type of workpiece. and next station is free spAuto Change color to the next. the station will be on Idle state [stIdle]. Sequence of distribution  First we select the color. and magazine 1 is not empty Black.8 8.  Simultaneously the conveyor will stop 1 sec after the workpiece passes the sensor at the end of conveyor [spStopConv]. different cylinders will be extended [spExtRed / spExtBlack / spExtSilver].1 Process description Distributing Station 8. silver. then black. For example if the station distributes a red previously. If a magazine is empty. the cylinder will be retracted [spRetract]. then it changes to black [spAuto]. If the magazine is empty.  Then the station will be on Idle state [spIdle].1.KG.1 Standalone mode of Distributing Station In standalone mode the Distributing Station distributes different types of workpieces one after another. red again. spIdle Station on Idle state Station in standalone mode.  When the workpiece arrives at the end of conveyor.  According to the color of the workpiece to distributed. • prolog-factory 107 . and magazine 3 is not empty Else spExtRed spExtBlack spExtSilver spMagEmpty Extend cylinder at magazine 1 Extend cylinder at magazine 2 Extend cylinder at magazine 3 Empty: Jump back to spIdle Workpiece at conveyor end (-3B1) spRetract spWait1s Retract the cylinder at the magazine Empty: Wait 1 sec Cylinder is retracted 1 sec later spStopConv Stop the conveyor motor © Festo Didactic GmbH & Co. and magazine 2 is not empty Silver. First red. Red. and so on.

Process description

8.1.2

MES mode of Distributing Station

In MES mode the Distributing Station cyclically asks for the task from the MES server
(in every second). It sends, the colors it has, and gets a task for one of these colors.
Sequence of distribution



108

Firstly the station asks for the next task. It is done by a program called
MES_CyclicRequestForOrder. This program asks for a task, if the station is on
Idle state [spIdle]. It means the station sends an “Ask for a Task” message
(M100.1).
If it has a workpiece with the selected color, it sends a “Task Started”
message (M100.10).
[spRedStart / spBlackStart / spSilverStart].
According to the color of the workpiece to distributed, different cylinders will
be extended
[spExtRed / spExtBlack / spExtSilver].
When the workpiece arrives at the end of conveyor, the “Task Finished”
message (M101.1) will be sent by the station to the MES server
[spSendFinished].
Then the cylinder will be retracted [spRetract].
Simultaneously the conveyor will stop 1 sec after the workpiece passes the
sensor at the end of the conveyor [spStopConv].
After that the station waits for next station [spWaitForValidation]. It has to
wait for validation, because, if the validation fails, it has to reproduce the
part.
Then the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

spIdle
Station on Idle state

MES_CyclicRequestForOrder
Cylcically request for task in
every second.

Station in MES mode, task received, and
next station is free

spMES
Registrate the color

Red, and magazine 1
is not empty

Black, and magazine 2
is not empty

Silver, and magazine 3
is not empty

Else

spRedStart

spBlackStart

spSilverStart

spMagEmpty

Entry: Send "Task
Started" (M100.10)

Entry: Send "Task
Started" (M100.10)

Entry: Send "Task
Started" (M100.10)

Empty: Jump back to
spIdle

Answer received

Answer received

Answer received

spExtRed

spExtBlack

spExtSilver

Extend cylinder at
magazine 1

Extend cylinder at
magazine 2

Extend cylinder at
magazine 3

Workpiece at
conveyor end (-3B1)

spSendFinished
Entry: Send "Task
Finished" (M101.1)
Answer received

spRetract

spWait1s

Retract the cylinder at
the magazine

Empty: Wait 1 sec

Cylinder is retracted

1 sec later

spStopConv
Stop the conveyor
motor

spWaitForVali...
Empty: Wait for next
station (validation)
Next station finished

© Festo Didactic GmbH & Co.KG. • prolog-factory

109

Process description

8.2

Testing Station

8.2.1

Standalone mode of Testing Station

In standalone mode the Testing Station checks only the orientation of the
workpieces. If the workpiece is hole side up, then the station transports it to the next
station. If the workpiece is hole side down, then the station will transport it to the
waste slide.
Sequence of validation



If a workpiece arrives, the station switches the conveyor belt motor on, and
waits for 1 sec [spConveyorOn]
Then the station checks the orientation of the workpiece with a laser sensor
[spCheck].
If the orientation of the workpiece is not ok:
o
o
o

The station extends the gate to the waste slide [spExtendGate].
The stopper cylinder will be retracted [spRetrStopper].
Then the station waits until the workpiece arrives on the waste
slide [spWait3B1].

If the orientation of the workpiece is ok:
o
o
o
o

110

The station waits for the next station [spWaitNext].
The stopper cylinder will be retracted [spRetrStopper].
The station waits until the next station starts working
[spWaitNotNext].
Then waits for 1 sec more [spWait1s].

The gate is retracted (if it was extended), the stopper is extended, and the
conveyor motor is stopped [spStop].
After the gate arrives to initial state, the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Stopper. and workpiece arrived spConveyorOn Switch on conveyor belt motor 1 sec later spCheck Check orientation Orientation is ok Orientation is not ok spWaitNext spExtendGate Empty: Wait until next station is free Extend gate to the waste slide Next station is free Save the workpiece type Gate extended spRetrStopper Retract the stopper cylinder Orientation was ok Orientation was not ok spWaitNotNext spWait3B1 Wait until next station starts working Empty: Wait until work piece on slide Next station is free workpiece on slide spWait1s Empty: Wait 1 sec After 1 sec spStop Retr.KG. ext. Gate. stop conveyor Gate in intial state © Festo Didactic GmbH & Co. • prolog-factory 111 .Process description spIdle Station in Idle state Station in standalone mode.

and waits for 1 sec [spConveyorOn] Then asks for task. If the color and orientation are good. It sends the “Ask for a Task” message (M100. the stopper is extended. the station switch the conveyor belt motor on. The gate is retracted (if it was extended).Process description 8.10) [spSendStarted]. Then the station sends “Task Finished” message (M101. The stopper cylinder will be retracted [spRetrStopper].1) [spSendFinished]. Simultaneously the station sends “Task Finished with Error” message (M101. Sequence of validation      If a workpiece arrives. and the conveyor motor is stopped [spStop]. Then waits for 1 sec more [spWait1s]. If the color or the orientation of the workpiece is not ok. If the station gets a task. © Festo Didactic GmbH & Co. the station will be on Idle state [spIdle]. and laser sensor [spCheck]. • prolog-factory . If the workpiece is hole side down. The stopper cylinder will be retracted [spRetrStopper]. Then the station checks the workpiece with the color sensor. or the color does not match.2.1 with error) [spSendError] If the color and the orientation of the workpiece are ok: o o o o o   112 The station waits for the next station [spWaitNext].KG.1) [spAskForOrder]. the station will transport it to the waste slide. the station transports the workpiece to the next station. After the gate arrives to initial state. Then the station waits until the workpiece arrives on the waste slide [spWait3B1]. or there is no task: o o o o The station extends the gate to the waste slide [spExtendGate].2 MES mode of Testing Station In MES mode the Testing Station asks for the color from the MES server. The station waits until the next station starts working [spWaitNotNext]. it sends back a “Task Started” message (M100.

or no task spWaitNext spExtendGate Empty: Wait until next station is free Extend gate to the waste slide Next station is free Registrate the workpiece type Gate extended spRetrStopper Retract the stopper cylinder Orientation and color were ok Orientation or color was not ok . or no task spWaitNotNext spWait3B1 spSendError Wait until next station starts working Empty: Wait until workpiece on slide Entry: Send "Task Finished with error" Next station is free workpiece on slide (M101.KG. • prolog-factory 113 . ext.10) Answer received spCheck Check color and orientation Orientation and color are ok Orientation or color is not ok.Process description spIdle Station on Idle state Station in MES mode. Gate.1) Answer received spSendStarted Entry: Send "Task Started" (M100. and workpiece arrives spConveyorOn Switch conveyor belt motor on 1 sec later spAskForOrder Entry: Send "Ask for a Task" (M100.1 with error) Answer received spWait1s Empty: Wait 1 sec After 1 sec spSendFinished Entry: Send "Task Finished" (M101. Stopper.1) Answer received spStop Retr. stop conveyor Gate in intial state © Festo Didactic GmbH & Co.

the station drills a hole in it. Then the indexing table rotates one step [sp_rotate1_1. The drilling unit moves up [spDrillUp]. Then the testing unit moves down. The station checks the hole [spCheck]. and if it is hole side up. and the drilling unit moves down [spDrillDown]. Ejects the workpiece to the next station [spEject]. Sequence of processing        If a workpiece arrives.3. Then the indexing table rotates one step again [sp_rotate1_3. • prolog-factory . Retracts the eject solenoid [spStop]. Switches the drill motor on.1 Standalone mode of Processing Station In standalone mode the Processing Station checks the hole in the workpiece.3 Processing Station 8. spRotate2_1]. After that it will be transported to the next station. the station waits for 1 sec [spWaits1s]. The Processing Station does the same in MES mode. spRotate2_3]. Releases the workpiece [spRelease]. Then the indexing table rotates one step again[sp_rotate1_2. and waits for 1 sec to reach the bottom [spTesting]. Switches the drill motor off [spDrillOff]. The testing unit moves up [spTestingUp]. Only one workpiece can be on the station in the same time. Waits until the next station is free [spWaitNext]. The station will be on Idle state [spIdle].Process description 8. Then it registrates the type of workpiece [spOk / spNotOk].KG. spRotate2_2]  If the orientation of the workpiece was ok: o o o o o      114 Fixes the workpiece [spFix]. © Festo Didactic GmbH & Co.

Process description 2 1 spIdle Station on Idle state Hole side up Hole side down spFix Workpiece arrives Fix the workpiece spWait1s Empty: Wait 1 sec After 1 sec spDrillDown 1 sec later Switch the drill on.KG. and drill unit moves down spRotate1_1 Give start signal for rotation of table Drill unit is in bottom position spDrillUp Table is not in position Drill unit moves up spRotate2_1 Reset start signal for rotation of table Drill unit is in top position spDrillOff Table is in position Switch the drill motor off spTesting Testing unit moves down spRelease After 1 sec Release the workpiece spCheck Empty: Check the hole spRotate1_3 Hole side up Hole side down spOk spNotOk Set workpiece type to ok Set workpiece type to not ok Give start signal for rotation of table Table is not in position spRotate2_3 Reset start signal for rotation of table spTestingUp Testing unit moves up After 1 sec spRotate1_2 Give start signal for rotation of table Table is not in position spRotate2_2 Reset start signal for rotation of table Table is in position 2 © Festo Didactic GmbH & Co. • prolog-factory Table is in position spWaitNext Empty: Wait until next station is free Next station is free spEject Eject workpiece to next station After 1 sec spStop Retract the eject solenoid 1 115 .

The Pick & Place Station does the same in MES mode.4 Pick & Place Station 8. Switches the vacuum off [spDrop]. The station switch the vacuum on to grip the instrument [spVacuumOn]. The handling unit grips the instrument with a vacuum.4. and switches the conveyor motor on [spSepRetr]. or wait until the signal comes from the vacuum sensor. The handling unit moves down to the instrument [spDown]. Retracts the horizontal cylinder [spRetract]. Switches the conveyor off [spConvOff2]. Then starts the conveyor [spConvOn]. Waits for 1 sec for workpiece transport [spWait1s_2]. After that it waits for 1 sec [spWait1s]. Extends the horizontal cylinder [spExtend]. Simultaneously if the next station is free [spWaitNext]. • prolog-factory . Then the station moves up with the instrument [spUp]. and inserts it on the workpiece.1 Standalone mode of Pick & Place Station In standalone mode the Pick & Place Station inserts a clock. Then the station will be on Idle state [spIdle]. a thermometer or a hygrometer into the workpiece. If the skipping of vacuum error is active ( xSkipVacError) then it will wait for 2 sec [spWait2s]. Then switch the conveyor off [spConvOff]. © Festo Didactic GmbH & Co. Moves down to the workpiece to insert the instrument on it [spDown2]. Sequence of insertion                  116 If a workpiece arrives the station extends the separator [spSepExt].KG. retracts the separator. Moves up [spUp2].Process description 8.

retract separator spVacuumOn Switch vacuum on Workpiece at conveyor end spWaits1s_2 Vacuum sensor is on Skipping the vacuum error is active (xSkipVacError) spWait2s Empty: Wait 2 sec 2 sec later Empty: Wait 1 sec 1 sec later spConvOff2 Switch the conveyor motor off spUp Move up with the instrument In upper position 2 © Festo Didactic GmbH & Co.Process description 2 1 spIdle spExtend Station on Idle state Extend the horizontal cylinder Workpiece arrives Horizontal cylinder is extended spSepExt spDown2 Extend the separator Move down with the instrument Not in upper position spConvOn spDrop Switch the conveyor motor on Workpiece passes the sensor before the separator Switch the vacuum off (drop the instrument) No vacuum spWaits1s spUp2 Empty: Wait 1 sec Move up 1 sec later In upper position spConvOff Switch the conveyor motor off spRetract spWaitNext Retract the horizontal cylinder Empty: Wait for next station spDown Next station is free Move down to instrument spSepRetr Vertical cylinder is not in upper position Switch conveyor on. • prolog-factory 1 117 .KG.

Rotates to the processing position [spRotateProc]. The Fluidic Muscle Press Station does the same in MES mode.Process description 8. the station will be on Idle state [spIdle].5 Fluidic Muscle Press Station 8. • prolog-factory .KG. If the next station is free.1 Standalone mode of Fluidic Muscle Press Station In standalone mode the Fluidic Muscle Press Station presses the instrument into the workpiece. Rotates to the upstream station [spRotateUp]. the station waits for 2 sec [spWait2s]. The pressing unit moves down [spPressDown]. It uses a pneumatic muscle for pressing. Then waits for the next station [spWaitDown]. If the pressure is reached.5. the horizontal cylinder is extended to the downstream station [spMoveDown]. Then closes the gripper and waits for another 1 sec [spClose]. The horizontal cylinder is retracted to the upstream station [spMoveUp]. © Festo Didactic GmbH & Co. The station opens the gripper [spOpen]. If the station reaches the initial position. the unit moves up [spPressUp]. and waits for 1 sec. Rotates to the downstream station [spRotateDown]. Sequence of pressing             118 If a workpiece arrives.

• prolog-factory 119 .KG.Process description spIdle Station on Idle state Workpiece arrives spWaits2s Empty: Wait 2 sec 2 sec later spClose Close the gripper 1 sec later spRotateProc Rotate to the processing position Rotary drive at processing position spPressDown Pressing unit moves down Pressure reached spPressUp Pressing unit moves up 2 sec later spRotateDown Rotate to the downstream station Rotary drive at downstream station position spWaitDown Wait for next station Next station is free spOpen Open the gripper 1 sec later spMoveUp Retract the horizontal cylinder Liner drive at upstream position spRotateUp Rotate to upstream position Rotary drive at upstream station position © Festo Didactic GmbH & Co.

the Storing Station searches for the color. Then checks whether there is still a workpiece or not [spCheckWp_c1]. or above the input of the next station [spMoveAboPlace_c1]. The station switches between each of the tasks one after the other. © Festo Didactic GmbH & Co. The station searches from the right side for a workpiece. Moves down to the workpiece [spMoveIn_c1]. Retracts the horizontal cylinder [spRetract_c2]. • prolog-factory . Then the station search for an empty tray for workpiece [spSearchIPlace]. If there is no free place. removal). If the next station is free. and transports it from the storage to the next station. Closes the gripper [spClose_c1]. The second task is the removal. else the station jumps back to Idle state [spIdle]. The station searches from the right side for an empty tray.6 Storing Station 8.6.1 Standalone mode of Storing Station In standalone mode there are two tasks (insertion. (It should count the number of fails of color checks. there is a problem with the color sensor. It clears the number of failed color checks [spCheckNum0_c1]. and increases the number of failed color checks [spRetract_c1]. The first task is inserting the incoming workpiece into the storage. black.  If the color check fails:  o o o       120 Retracts the horizontal cylinder. Each colors are sorted on different shelves (from the top: red.KG. Moves above the empty tray. the workpiece will be transported to the next station. If there is no free place for the workpiece. because if it failed three times in a row.Process description 8. Then it checks the color [spCheckColor_c1]. and the station has to go to error state. Sequence of insertion    If a workpiece arrives the station moves above the workpiece [spMoveAboveIn_c1]. Moves up with the workpiece [spMoveAboveIn_c2].) Then the station extends the horizontal cylinder [spExtend_c1]. silver). which occurs the most. If there is still a workpiece jumps back before color check [spExtend_c1]. it will be transported to the next station.

Horizontal cylinder extended 1 sec later spMovePlace_c1 Workpice color was detected spSearchIPlace Search free place for insertion Else spWaitNext_c1 If there is no free place select the next station for insertion.Process description  If the workpiece was transported to the next station : o Retracts Waits until the next station is free [spWaitNext_c1]. Moves to the tray or to the input of the next station [spMovePlace_c1]._c1 Move above the upstream station pos.KG.Pl. Retracts the horizontal cylinder [spRetract_c3].  If the workpiece was transported to a tray : o   Registrates the insertion [spRegIns_c1]. insertion is selected. Then the station will be on Idle state [spIdle]. Else Move to the place spRetract_c1 Retract horizointal cylinder Motion finished In entry action increase the number of color checks Horizontal cylinder retracted spMoveIn_c1 spCheckWp_c1 Move to the upstream station position Empty: Check if there is a workpice or not Open the gripper 1 sec later If inserted into the storage Motion finished spClose_c1 There is no workpiece (it was removed) spOpen_c1 There is a workpiece Else spRegIns_c1 Registrate the insertion Close the gripper 1 sec later spMoveAb.In_c1 spMoveAb.    Extends the horizontal cylinder [spExtend_c2]. 1 2 spIdle spRetract_c2 Station on Idle state Retract horizointal cylinder Station in standalone mode. spRetract_c3 Retract horizointal cylinder Horizontal cylinder retracted Motion finished 1 2 © Festo Didactic GmbH & Co. Move above the place Motion finished Motion finished spCheckNum0_c1 Insertion into the storage not to the next station Reset the number of color checks Wait for next station spExtend_c1 Extend the horizontal cylinder Next station is free Horizontal cylinder extended spExtend_c2 spCheckColor_c1 Extend the horizontal cylinder Check and registrate the type of the wp. and workpiece arrives Horizontal cylinder retracted spMoveAb.In_c2 Move above the upstream station pos. Opens the gripper [spOpen_c1]. • prolog-factory 121 .

Moves above the input of the next station [spMoveAboveOut_d1]. Then the station will be on Idle state [spIdle]. If there is not a workpiece in the storage with the specific color of the order: o             122 The station jumps back to Idle state [spIdle]. Registrates the removal [spRegRam_d1]. which occurs the most [spSelColor_d1]. which has a workpiece with the same color [spSearchRPlace]. Then it searches for a tray.KG. © Festo Didactic GmbH & Co. • prolog-factory . Retracts the horizontal cylinder [spRetract_d2]. Lifts up the workpiece [spMoveAbovePlace_d1]. Retracts the horizontal cylinder [spRetract_d1]. Closes the gripper [spClose_d1]. Extends the horizontal cylinder [spExtend_d1]. drops the workpiece [spOpen_d1]. Extends the horizontal cylinder [spExtend_d2]. Moves to the input of the next station (uses only the linear axes) [spMoveOutLin_d1].Process description Sequence of removal    If the removal is active the station selects the color. Opens the gripper. Then the station moves to the workpiece [spMovePlace_d1].

removal is selected.KG.OutLin_d1 Extend the horizontal cylinder Move to downstream station (only linear) Horizontal cylinder extended Motion finished spClose_d1 spOpen_d1 Close the gripper Open the gripper 1 sec later 1 sec later spMoveAb.Pl. and the storage is not empty Registrate the removal spSelColor_d1 spRetract_d1 Select color (which occurs the most) Retract the horizontal cylinder Horizontal cylinder retracted spSearchRPlace spMo. with the selected color Move above downstream station Else Motion finished spMovePlace_d1 spExtend_d2 Move to the place Extend the horizontal cylinder Motion finished Horizontal cylinder extended spExtend_d1 spMo.Process description 1 2 spIdle spRegRem_d1 Station on Idle state Station in standalone mode. • prolog-factory Horizontal cylinder retracted 2 123 .Out_d1 Search for the selected color in storage If there is a wp._d1 spRetract_d2 Move above the place Retract the horizontal cylinder Motion finished 1 © Festo Didactic GmbH & Co.Ab.

) Then the station extends the horizontal cylinder [spExtend_a1]. • prolog-factory . The second task is the removal. If there is no free place. After the station detects the color. The station switches between each of the tasks one after the other. Then the station asks for the next order from the MES (M100. If there is no order for the color. If there is an order for the specific color of the workpiece. (It should count the number of fails of color checks. If there is an order. the station asks the MES server for an empty tray. Sequence of insertion    If a workpiece arrives the station moves above the workpiece [spMoveAboveIn_a1]. the workpiece will be transported to the next station. it asks for a task from MES server. it will serve it. Then checks whether there is still a workpiece or not [spCheckWp_a1].1) [spAskForOrder_a1).KG.6.2 MES mode of Storing Station In MES mode there are two tasks (insertion.Process description 8. there is a problem with the color sensor. If there is still a workpiece jumps back before color check [spExtend_a1]. because if it failed three times in a row. the Storing Station asks the MES server for an order. and increases the number of failed color checks [spRetract_a1]. If the next station is free. removal). and the station has to go to error state. and inserts the workpiece into this tray. It clears the number of failed color checks [spCheckNum0_a1]. © Festo Didactic GmbH & Co. the station transports it from the storage to the next station. The first task is inserting the incoming workpiece into the storage. Then it checks the color [spCheckColor_a1].  If the color check fails:  o o o  124 Retracts the horizontal cylinder. else the station jumps back to Idle state [spIdle].

Moves above the input of next station [spMoveAboveOut_a1]. Retracts the horizontal cylinder [spRetract_a5]. Opens the gripper [spOpen_a2]. Moves down to the workpiece [spMoveIn_a2]. Moves above the empty tray. Then the station jumps back to Idle state [spIdle]. the workpiece will be transported to the next station. If the workpiece was transported to the next station : o Retracts Waits until the next station is free [spWaitNext_a4]. Then the station will be on Idle state [spIdle]. o If the color of workpiece and order match: o                      The stations ends “Task Started” message (M100. Send a “Task finished” message (M101.Process description  If there is an order for the station: o It asks for the parameters of the order (M100.  If the workpiece was transported to a tray : o o   Registrates the insertion [spRegIns_c1]. Waits until the next station is free [spWaitNext_a1].31) [spRegInsMES]. or above the input of the next station [spMoveAboPlace_a1]. Then registrates the color from the answer [spSaveColor_a1]. Opens the gripper.    Extends the horizontal cylinder [spExtend_a3]. Extends the horizontal cylinder [spExtend_a2]. If there is no empty tray.10) [spSendStarted_a1] Moves to the workpiece [spMoveIn_a1]. Moves to the tray or to the input of the next station [spMovePlace_a1]. Moves up with the workpiece [spMoveAboveIn_a3].1) [spSendFinished_a1]. Then the station calculates the row and column number from the tray number [spCalcColRowI_a1]. Retracts the horizontal cylinder [spRetract_a2]. drops the workpiece [spOpen_a1]. Retracts the horizontal cylinder [spRetract_a3]. Moves to the input of the next station (use only the linear axes) [spMove. Then the station asks for an empty tray for the workpiece from MES [spSearchMESIPlace]. • prolog-factory 125 . Closes the gripper [spClose_a1].21) [spAskForParameters_a1]. Retracts the horizontal cylinder [spRetract_a4]. And simultaneously registrates the insertion in MES(M100.OutLin_a1]. Closes the gripper [spClose_a2]. Lifts up the workpiece [spMoveAboveIn_a2]. © Festo Didactic GmbH & Co.KG.

insertion is selected. (M100._a1 Entry: Ask for param.Process description spIdle Station on Idle state Station in MES mode.21) Answer received spSaveColor_a1 Registrate color from answer Task and workpiece color do not match Else spSearchMESIPla. and workpiece arrives spMoveAb.In_a1 Move above the upstream station pos. Motion finished spCheckNum0_a1 Reset the number of color checks spExtend_a1 Extend the horizontal cylinder Horizontal cylinder extended spCheckColor_a1 Check and registrate the type of the wp.1) Answer received There is no task for the station Else spAskForPara. Answer received spMoveIn_a1 Move to the upstream station position Motion finished 1 126 2 3 4 © Festo Didactic GmbH & Co. spSendStarted_a1 Search free place for insertion Entry: Send "Task Started" (M100. • prolog-factory .10) Answer received spCalcColRowI_a1 Calculate the row and column number If there is no free place select the next station for insertion. 1 sec later Workpice color was detected Else spRetract_a1 Retract horizointal cylinder In entry action increase the number of color checks Horizontal cylinder retracted spCheckWp_a1 Empty: Check if there is a workpice or not There is no workpiece (it was removed) spAskForOrder_a1 There is a workpiece Entry: Ask for an order (M100.KG.

1 sec later Motion finished spMoveAb.OutLin_a1 Move to downstream station (only linear) spExtend_a3 Motion finished Extend the horizontal cylinder spOpen_a1 Horizontal cylinder extended Open the gripper spMovePlace_a1 1 sec later Move to the place spRetract_a3 Retract horizointal cylinder Motion finished spOpen_a2 Horizontal cylinder retracted Open the gripper spSendFinish. Horizontal cylinder retracted Motion finished spMoveAb._a1 Entry: Send "Task Finished" (M101._a1 spWaitNext_a1 Move above the place Move above the place Motion finished Next station is free Insertion into the storage not to the next station spExtend_a2 Else Extend the horizontal cylinder spWaitNext_a2 Horizontal cylinder extended Move above the place Next station is free spMov.In_a3 spRetract_a2 Move above the upstream station pos.In_a2 Close the gripper Move above the upstream station pos.Ab.Process description 1 2 3 spMoveIn_a2 spClose_a1 Move to the upstream station position Close the gripper Motion finished 4 1 sec later spClose_a2 spMoveAb.Pl. Retract horizointal cylinder Horizontal cylinder retracted Motion finished spRetract_a4 spMov.1) 1 sec later If inserted into the storage spRegIns_a1 spRegInsMES Registrate the insertion Entry: Registrate the insertion in MES Else Answer received spRetract_a5 Retract horizointal cylinder Horizontal cylinder retracted © Festo Didactic GmbH & Co.KG. • prolog-factory 127 .Out_a1 Retract horizointal cylinder Move above the downstream station pos.

Retracts the horizontal cylinder [spRetract_b1]. If there is not a workpiece in the storage with the specific color of the order: o                128 The station jumps back to Idle state [spIdle]. Closes the gripper [spClose_b1]. © Festo Didactic GmbH & Co.10) [spSendStarted_b1]. Then it asks from the MES for a tray. Then the station will be on Idle state [spIdle]. Sends a “Task finished” message (M101.KG. Extends the horizontal cylinder [spExtend_b2]. Retracts the horizontal cylinder [spRetract_b2]. Then the station sends a “Task started” message (M100. • prolog-factory . Extends the horizontal cylinder [spExtend_b1].1) [spSendFinished_b1]. Moves above the input of the next station [spMoveAboveOut_b1]. and there is an order the station asks for the parameters of the order (M100. Lifts up the workpiece [spMoveAbovePlace_b1]. which has a workpiece with the same color (M100. Opens the gripper.21) [spAskForParameters_b1]. Registrates the removal [spRegRam_b1]. Moves to the input of the next station (uses only the linear axes) [spMoveOutLin_b1].Process description Sequence of removal    If the removal is active. Moves to the workpiece [spMovePlace_b1]. And simultaneously registrates the removal in MES [spRegRemMES]. drops the workpiece [spOpen_b1].30) [spSearchRPlace].

OutLin_b1 If there is a wp.Ro.Co.30) Motion finished spExtend_b2 Answer received Extend the horizontal cylinder spCal.Pl.21) spRetract_b1 Answer received Retract the horizontal cylinder spSea.1) Answer received Close the gripper 1 sec later spMoveAb.Out_b1 Answer received Move above downstream station spSearchMESRPla.Process description 1 2 spIdle Station on Idle state Station in MES mode. with the selected color spSendStarted_b1 Entry: Send "Task Started" (M100. and there is an order spRegRem_d1 spRegRemMES Reistrate the removal Entry: Registrate the removal in MES spAskForPara._b1 Entry: Send "Task Finished" (M101. spMo.R_b1 Horizontal cylinder extended Calculate the column and row from param.KG. Entry: Ask for place from MES (M100. removal is selected._b1 Horizontal cylinder retracted Entry: Search for tray with MES spMo._b1 Move above the place Motion finished 1 © Festo Didactic GmbH & Co.Ab._b1 Answer received Entry: Ask for parameters (M100.10) Answer received spMovePlace_b1 Move to the place Motion finished spExtend_b1 Extend the horizontal cylinder Horizontal cylinder extended spClose_b1 Else Move to downstream station (only linear) Motion finished spOpen_b1 Open the gripper 1 sec later spRetract_b2 Retract the horizontal cylinder Horizontal cylinder retracted spSendFinish.MESRPl. • prolog-factory 2 129 .

After the workpiece arrives to check point it waits for 1 sec [spWait1s]. so we can check whether they are working or not. Then the station waits for the next station [spWaitNext].7 Separating Station 8. (It waits for the Storing Station.  If the color of the workpiece is black or silver: o Extends the separator gate. the station waits for 2 sec [spWait2s_2]. switches the perpendicular conveyor on.KG. the station retracts the stopper [spRetrStop]. After the workpiece arrives at the end of either of conveyor.7. extracts the stopper and stops the conveyors [spStop]. and transports the red workpiece to the Sorting Station.) Then switches the main conveyor motor on [spConv1On]. Then it checks the color and material [spCheck]. In this case the station uses all sensors. • prolog-factory . After the next station is free.1 Standalone mode of Separating Station In standalone mode the Separating Station transports the black and silver workpieces to the Robot Station with the separator gate. 2 sec later it retracts the separator. © Festo Didactic GmbH & Co.Process description 8. and registrates that the workpiece was good [spExtGate]. Sequence of separation     After a workpiece arrives the station waits for 2 sec [spWait2s]. If the color of the workpiece is red: o      130 Registrates that the workpiece was not good [spNotOk]. After that the station will be on Idle state [spIdle].

Next station is free spRetrStop Retract the stopper Workpiece arrives at the end of any conveyor spWait2s_2 Empty: Wait 2 sec 2 sec later spStop Retr. the type of the workpiece Workpiece is black or silver Else spExtGate spNotOk Extend the separator and switch conv. 2 on Save that the workpiece was not good Registrate the workpiece type Separator is not retracted spWaitNext Wait until next station is free Wait for sorting or for the robot buffer. and workpiece arrives spWait2s Empty: Wait 2 sec 2 sec later spConv1On Switch the main conveyor on Workpiece at check position spWait1s Empty: Wait 1 sec 1 sec later spCheck Check and reg. ext.KG. • prolog-factory 131 . stop conveyors Gate in intial state © Festo Didactic GmbH & Co. Stopper.Process description spIdle Station on Idle state Station in MES mode. Gate.

Process description 8. material of the workpiece and the order are same:     o Extends the separator gate.) Then switches the main conveyor motor on [spConv1On].KG. If the color. Sequence of separation in MES mode   After a workpiece arrives the station waits for 2 sec [spWait2s]. After the next station is free. After that the station will be on Idle state [spIdle]. switches the perpendicular conveyor on. it sends a “Task Started” message (M100. 2 sec later it retracts the separator. Then the station waits for the next station [spWaitNext]. extracts the stopper and stops the conveyors [spStop].1) with or without error [spSendFinished]. the station retracts the stopper [spRetrStop].7. the station inserts the workpiece into the buffer (M100. If it gets a task. the station transports it to the Robot Station with the separator gate. © Festo Didactic GmbH & Co.2 MES mode of Separating Station In MES mode the Separating Station asks the server about the next order.36) of the Robot Station [spInsertFIFO]. If the workpiece was good. If the color of the workpiece is not correct. According to the type of the workpiece. the station waits for 2 sec [spWait2s_2]. If the coming workpiece has the same color than the order. After the workpiece arrives to check point it waits for 1 sec [spWait1s]. (It waits for the Storing Station. Then it checks the color and material [spCheck]. Then the station asks for an order (M100.10) [spSendStarted]. material of the workpiece and the order are different: o        132 Registrates that the workpiece was not good [spNotOk]. the station sends a “Task Finished” message (M101. it will be transported to the Sorting Station.  If the color. After the workpiece arrives at the end of either of conveyor. and registrates that the workpiece was good [spExtGate].1) [spAskForOrder]. • prolog-factory .

Process description

2

1

spIdle
spWaitNext

Station on Idle state

Wait until next station
is free

Station in MES mode, and workpiece
arrives

Wait for sorting or for
the robot buffer.

Next station is free

spWait2s

spRetrStop

Empty: Wait 2 sec

Retract the stopper
2 sec later
Workpiece arrived to the
end of either of conveyor

spConv1On

spWait2s_2

Switch the main
conveyor on

Empty: Wait 2 sec
Workpiece at check
position
2 sec later

spWait1s

spStop

Empty: Wait 1 sec

Retr. Gate, ext. Stopper, stop conveyors
1 sec later
Gate in intial state

spAskForOrder

spInsertFIFO

Entry: Send "Ask For a
Task" (M100.1)

Entry: Insert wp. In
rob. FIFO (M100.36)

If the workpiece was good

Answer received
Answer received

spSendStarted
Entry: Send "Task
Started" (M100.10)

spSendFinished

If there is a task for the
station.

Entry: Send "Task
Finished" (M101.1)

If there was a task.
Accorindg to the workpiece
type, with or without error.

Answer received
Answer received

spCheck
Check and reg. the
type of the workpiece

Workpiece is good

Else

spExtGate

spNotOk

Extend the separator
and switch conv. 2 on

Reg. that the workpiece was not good

Registrate the workpiece type

Separator is not
retracted

2

© Festo Didactic GmbH & Co.KG. • prolog-factory

1

133

Process description

8.8

Sorting Station

8.8.1

Standalone mode of Sorting Station

In standalone mode the Sorting Station sorts out the different types of workpieces
to different slides.
The Sorting Station does the same in MES mode.
Sequence of sorting







134

If a workpiece arrives the station switches the conveyor motor on and waits
for 2 sec [spConvOn].
Then checks the color and the material with an inductive-, and an optical
sensor.
According to the material and color, the station extends a separator or not
[spExtRed / spExtBlack / spExtSilver].
Then retracts the stopper [spRetrStoper].
Waits for the falling edge of the sensor at the slides (-B4) [spWaitNotB4].
Retracts the separator (if it was extended), and extends the stopper
[spStop].
If all separators are retracted, the station will be on Idle state [spIdle].

© Festo Didactic GmbH & Co.KG. • prolog-factory

Process description

spIdle
Station on Idle state

Workpiece arrives

spConveyorOn
Switch the conveyor
motor on

Workpiece is red

Workpiece is black

Workpiece is silver

spExtRed

spExtBlack

spExtSilver

Extend the first
separator

Extend the second
separator

Do not extend any
separator

First separator is
extended

Second separator is
extended

spRetrStoper
Retract the stopper
The sensor at the slide
is on

spWaitNotB4
Empty: Wait until
sensor is off at slide
The sensor at the slide
is off

spStop
Retr. Sep., ext. Stopper
switch conveyor off
Separators are
retracted

© Festo Didactic GmbH & Co.KG. • prolog-factory

135

And waits until a workpiece arrives at conveyor belt [110]. Then the station waits until output slide of the Robot is free [125]. and outline one after the other. and place a new empty pallet on the input slide. The Robotino 1 moves an empty pallet from the input slide to the Robot Station. And the Robot moves the commissioned pallet to the output slides [135]. Then waits until the Robot finishes the task [140]. The station sends the Robotino 1 to move the empty pallet to Robot Station [15]. The Robot moves it to the next pallet place. And waits until the writing is finished [150]. and then commissioned it with for workpieces. and moves back to the output slide of the Robot Station.1 Standalone mode of Robot Station and Robotinos In standalone mode the Robot Station and the Robotinos work only in a simple sequence (in an infinite loop).KG. There is only one pallet in the system in the same time. And calculates the next workpiece position [120]. After that the station writes the RFID data into the pallet [145].9 Robot Station and Robotinos 8. © Festo Didactic GmbH & Co. The Robot moves the commissioned pallet to the output slide.  If there is still a free place on the pallet: o       136 The station jumps back to Idle state [10].  Then it waits until the workpiece arrives at the end of input slide [100].  If there is an error with the communication between Robotino 1 and the PLC: o     The station jumps back to Idle state [10]. After that the Robotino 2 removes the pallet from the stock.  If there is an error with the communication between Robotino 1 and the PLC: o  And waits until the Robotino 1 transports the empty pallet to the Robot station [20].9. After that it lifts up the pallet stopper [130]. Then the Robot Station starts the cycle again. stock position. The station jumps back to insert a new workpiece [100]. In this case all positions will be tested in standalone mode. and transports it to the next outline. Then it waits for an empty pallet on input slide [10]. The Robot moves the pallet to the next empty pallet place [105]. The Robotino 1 transports it to the next position of the stock. Then the Robot moves the workpiece to the next free place of the pallet [115].Process description 8. • prolog-factory . The operator should remove manually the delivered pallet from the outline. Between the cycles the Robot Station and Robotinos switch to the next pallet position. Sequence of robot station and robotinos    First the station initializes the variables [1].

the station calculates the outline position [185]. The station switches between the storage. If all storage positions. and output positions one after the other to check all positions.KG. © Festo Didactic GmbH & Co. If there is an error with the communication between Robotino 2 and the PLC: o The station jumps back to sending the task to Robotino 2 [185]. After the Robotino 2 finishes the task. And then the station calculates the next storage and output position [250]. After the Robotino 1 finishes the task.  If there is an error with the communication between Robotino 1 and the PLC: o    The station jumps back to sending the task to Robotino 1 [175]. Robotino 2 moves the pallet from the stock to the outline [190].  If there is an error with the communication between Robotino 2 and the PLC: o      The station jumps back to sending the task to Robotino 2 [185]. After the pallet arrives at the bottom of the outline slide (RFID tag is detected). Then the station sends the commissioned pallet to the stock with Robotino 1 [175]. or all outlines have been already used. • prolog-factory 137 . and arrives back to Robot Station [180]. starts with the first place again [170]. Then jump back to Idle state [10] from an empty step [300]. The station switches between the pallet position one after the other to check all positions. And waits until the pallet arrives at the bottom of output slide [160]. If all pallet places have been already used. the station calculates the outline position [200].  And waits until Robotino 1 finishes the task. the station reads out the RFID data from the pallet [205].  And waits until Robotino 2 finishes the task. start again with the first storage position or outline [255]. If there is an error with the communication between Robotino 1 and the PLC: o The station jumps back to sending the task to Robotino 1 [175].Process description       Then it lifts down the pallet stopper [155]. If Robotino 2 is ready. Then calculates the next pallet place [165]. and arrives back to Robot Station [195].

> 4 change to pal. to outline with Robotino 2 135 Move the pallet to output slide 2 Robotino 2 is busy (started the task) 1 5 138 Error in Robotino 2 communication 3 4 © Festo Didactic GmbH & Co. • prolog-factory . Pos 1 110 Empty: Wait for workpiece at conveyor Next storage position is free.KG. The next position on pallet is stored in byPalIndex After that the Robotino 1 will go back to Robot Station Robotino 1 is busy (started the task) Robot finished the task 180 120 Empty: Wait until Robotino 1 finished Switch to the next position on pallet.Process description 2 1 1 140 Initalize variables Wait until robot task finished Robot finished the task 10 145 Wait for Auto Mode Write RFID data into pallet Station in standalone mode. and Robotino 1 is ready 175 Workpiece available at conveyor belt Send pallet to the stock with Robotino 1 115 Move workpiece to the next position on pall. Robotino 1 is ready The index is 1 again Error in Robotino 1 communication Else Error in Robotino 1 communication 125 Empty: Wait for Robot outslide is free 185 Robot's output slide is free Calculate the outline position 130 Lift up the pallett stopper Robotino 2 is ready 190 Pallett stopper in upper position move pall. and buffer and storage are empty 15 150 Send Robotino 1 for an empty pallet Wait RFID write finished RFID write finished Robotino 1 is busy (started the task) Error in Robotino 1 communication 155 20 Lift down the pallet stopper Empty: Wait until Robotino 1 finished Robotino 1 is ready 160 Error in Robotino 1 communication Wait until pallet at slide end 100 Wait for empty pallet on Robot slide Pallett stopper in lower position and pallett at slide end 165 Empty pallet is on Robot's input slide Switch to the next pallet position 105 Move the empty pallet to next pallet position The next pallet position is stored in byPalPos 170 Robot finished the task If next pos.

Process description © Festo Didactic GmbH & Co. • prolog-factory 139 .KG.

and the last delivery was more than 1s before. If there is an empty pallet on input slide.  If there is no free place: o       140 The station jumps back to Idle state [10]. After that the station will be on Idle state [10]. Then the station waits for the answer from MES [125].2 MES mode of Robot Station In MES mode there are three tasks (empty tray insertion. the output slide is free. and it moves the specific pallet to the output slide. The Robot moves the pallet from the input slide to the specific pallet place [110]. If there is a pallet at a pallet place.Process description 8. and moves the workpiece to the specific place. a workpiece on the conveyor.9. the station searches for the next free pallet place [100]. The second task is the commissioning. commissioning and delivery of commissioned pallet). and there is a free pallet place. The empty tray insertion has the highest priority. then the commissioning. Waits until the Robot finishes the task [115]. the Robot asks for an insertion task form MES. and there is a free pallet place. and registrates the insertion in MES server.KG. The station tries to avoid serving the same task twice in a row. the station moves the pallet to the free place. the station checks the return code from the Robot [116]. If there is a pallet on a pallet place. After the Robot finishes. The third task is the delivery of commissioned pallet. Sequence of empty pallet insertion  If there is an empty pallet on the input slide. and the last insertion was more than 1s before.31) [120]. After the return code is 0 the station books the pallet in pallet buffer of MES server (M100. • prolog-factory . © Festo Didactic GmbH & Co. and the delivery. The first task is inserting the incoming empty pallet to a free pallet place. the Robot ask for a delivery task from MES.

Process description 10 Station on Idle state MES mode is active.31) 125 Empty: Wait MES request finished Answer received © Festo Didactic GmbH & Co. • prolog-factory 141 . there is an empty pallet on input slide.KG. buffer (M100. and one of the pallet places is free 100 Search for the next free pallet place There is a free place Else 110 Move the pallet from the input to the place 115 Wait until Roboto finishes the task Robot finished the task 116 Check robot return code Return code = 0 120 book pallet on MES pall.

After the answer received. • prolog-factory . The station jumps back to Idle state [10]. Checks the return code from the Robot [256]. And waits for the answer [275]. the station removes the workpiece from the FIFO of MES server (M100. and the last workpiece insertion was more than 1s before. there is a pallet on a pallet place. Then it asks for a commissioning task from MES (M100. After the return code is 0. And waits for the answer [220].Process description Sequence of commissioning a pallet    If there is a workpiece on the conveyor belt. And waits for the answer from MES [265]. Then the station moves the workpiece to the pallet [250].2) [205].1) [270]. The station sends a “Task started” message (M100.  If there is no task for commissioning: o   The station asks the MES. And waits for the answer [210].35) [215]. where to place the workpiece (M101.37) [260]. And waits for the answer [230]. Then the station sends a “Task finished” message (M101. And waits until the Robot finishes the task [255].10) to the MES [225].  If there is no place for insertion: o           142 The station jumps back to Idle state [10]. © Festo Didactic GmbH & Co. the station will be on Idle state [10]. the station registrates the start of commissioning [200].KG.

10) 2 © Festo Didactic GmbH & Co.1) Else 225 Send "Task Started" (M100. • prolog-factory 1 275 Empty: Wait MES request finished Answer received 143 . and last workpiece insertion was more than 1 sec before. other is a pallet.Process description 2 1 10 230 Station on Idle state MES mode is active.35) 265 Empty: Wait MES request finished 220 Empty: Wait MES request finished Answer received 270 Answer received There is a place for insertion Send "Task Finished" (M101.KG. where to place wp. there is a workpiece on conveyor. (M101. Empty: Wait MES request finished Answer received 200 250 Registrate the start of insertion Move the workpiece to the pallet 205 255 Check if order in MES available (M100.37) 215 Ask MES.2) Empty: Wait until robot finish Robot finished the task 210 256 Empty: Wait MES request finished Check Robot return code Answer received There is a task for Insertion Return code = 0 Else 260 Remove workpiece from FIFO (M100.

And waits for the answer [310]. • prolog-factory .10) to the MES [325]. After that it checks the return code from the Robot. The station writes the RFID data into the pallet [365].KG.Process description Sequence of delivering the commissioned pallet    If there is a pallet on a pallet place. The station asks the MES. Then the station waits until the Robot finishes the task [360]. © Festo Didactic GmbH & Co. And waits until the pallet reaches the bottom end position of the output slide [380]. and the last delivery was more than 1s before. And waits until the writing is finished [370]. the output slide is free. And waits until the stopper reaches the upper position [350]. Then it sends a “Task finished” message (M101. which pallet should be delivered (M100. Then the station updates the buffer position (removes the delivered pallet) in MES (M100. And waits for the answer [330]. the Robot moves the pallet to the output slide [355]. Then it lifts up the pallet stopper [345]. and waits until it is 0 [361].31) [390]. The station sends a “Task started” message (M100. After the answer received. And waits for the answer [320]. the station will be on Idle state [10]. And waits for the answer [405]. the station registrates the start of delivery [300]. Asks for a delivery task from MES (M100.  If there is no task for delivery: o                   144 The station jumps back to Idle state [10]. If the stopper is in upper position. Then lifts down the pallet stopper [375].1) to the MES [400]. And waits for the answer [395].30) [315].2) [305].

Process description 2 1 10 355 Station on Idle state MES mode is active.1) 350 Wait pallet stopper in upper end position Pallet stopper in upper position 2 1 Pallet stopper in upper position 405 Empty: Wait MES request finished Answer received © Festo Didactic GmbH & Co.30) RFID write finished 375 Lift down pallet stopper 320 Empty: Wait MES request finished Answer received 380 Wait until pallet at slide end 325 Send "Task started" (M100.KG. output slide is free. • prolog-factory 145 .10) Pallett stopper in lower position and pallett at slide end 390 Update buffer in MES (M100.31) 330 Empty: Wait MES request finished Answer received 395 Empty: Wait MES request finished 345 Lift up pallet stopper Answer received 400 Send "Task fininshed" (M101. and last delivery was more than 1 sec before.2) Check Robot return code Return code = 0 310 365 Empty: Wait MES request finished Write RFID datat into pallet Answer received Ther is a task Else 370 Wait RFID write finished 315 Search for the pallet to move (M100. Move commissioned pallet to out slide 300 360 Registrate the start of delivery Empty: Wait until robot finishes Robot finished the task Robot finished the task 305 361 Check if order in MES available (M100. there is a pallet on pall. place.

© Festo Didactic GmbH & Co. Sequence of commissioned pallet transportation to storage   If a pallet is on the output slide of Robot Station. And waits until the answer received from MES [250]. And waits until the Robotino is busy [235].1) to MES [255]. After that the Robotino moves back to Robot Station.2) [200]. Then the PLC books the Robotino Storage position in MES server (M100. the Robotino asks the MES about next task (M100. And waits until the answer received from MES [225]. If a pallet is on the output slide of Robot Station. the Robotino asks the MES about next task. empty tray transportation to Robot Station). Then the Robotino will be on Idle state.KG. In this case the Robotino does not have any communication with the MES server. the Robotino moves the empty pallet to the Robot Station.Process description 8.  If there is a communication error between Robotino and PLC: o      146 The station jumps back to Idle state [10]. Then sends a “Task finished” message (M101.3 MES mode of Robotino 1 In MES mode there are two tasks for Robotino 1 (commissioned pallet transportation from Robot Station to Robotino Storage. and registrates it in MES. • prolog-factory . the Robotino transports the pallet to a free storage position. If there is a task. Then the Robotino moves the commissioned pallet from the Robot Station to the Robotino Storage [230].  If there is no task: o      Then the PLC searches for a free place in Robotino Storage [215]. If an empty pallet is available on the input slide. The station jumps back to send the task again [230].31) [245]. The commissioned pallet transportation has a higher priority.10) to MES [220].  If there is a communication error between Robotino and PLC: o The station jumps back to send the task again [230]. And waits until the answer received from MES [210]. Sends a “Task started” message (M100.9.  Then the station waits until Robotino finishes [240]. And waits until the answer received from MES [260]. and the input slide of the Robot Station is free.

10) 250 Empty: Wait MES request finished 225 Answer received Empty: Wait MES request finished Answer received 2 255 Send "Task finished" (M101.KG. and there is a free place in the storage 230 Robotino moves the pallet to sock. there is a pallet on output slide at Robot Station.Process description 2 1 10 Station on Idle state MES mode is active.31) 220 Free place found Send "Task started" (M100. 200 Ask for a task from MES (M100.1) 1 Free place found 260 Empty: Wait MES request finished Answer received © Festo Didactic GmbH & Co. • prolog-factory 147 .2) 235 Empty: Wait until Robotino is busy 210 Empty: Wait MES request finished Robotino is busy Error in Robotino communication 240 Answer received Empty: Wait until Robotino finished Ther is a task Else 215 Robotino finished Find next free shelf in storage Free place found Error in Robotino communication 245 Book pallet on MES stock buffer (M100.

the Robotino moves the empty pallet to the Robot Station [100]. the station will be on Idle state [10].Process description Sequence of empty pallet transportation to the Robot Station   If an empty pallet is available on the input slide. 10 Station on Idle state MES mode is active.KG. After the Robotino finishes. and the input slide of Robot Station is free 100 Robotino moves empty pallet to Robot 105 Empty: Wait until Robotino is busy Robotino is busy Error in Robotino communication 110 Empty: Wait until Robotino finished Robotino finished 148 Error in Robotino communication © Festo Didactic GmbH & Co.  Then the PLC waits until the Robotino is finished [110].  If there is a communication error between Robotino and PLC: o The PLC jumps back to send the task again [100].  If there is a communication error between Robotino and PLC: o  The PLC jumps back to send the task again [100]. there is a pallet on input slide. • prolog-factory . And the PLC waits until the Robotino is busy [105]. and the input slide of the Robot Station is free.

the Robotino selects the first free output slide from the left [115]. Sequence of pallet delivery to output slides   If there is a free output slide. Before the delivery the PLC asks the MES server about the destination of the pallet. the Robotino selects that.  If there is a communication error between Robotino and PLC:    o The PLC jumps back to send the task again [130].  After that the Robotino selects the destination slide.10) to the MES [120]. And waits for the answer from MES [125].  If there is no task for delivery: o  The station jumps back to Idle state [10]. If there is not a predefined slide.41) [100].9. If the destination is not defined.  If there is a communication error between Robotino and PLC: o      The PLC jumps back to send the task again [130].Process description 8.31) [145]. • prolog-factory 149 .31) to MES [155]. And the PLC waits until Robotino is busy [135]. And waits for the answer from MES [150]. © Festo Didactic GmbH & Co. And waits for the answer from MES [110]. If there is a predefined slide. And waits for the answer from MES [160].  Then the PLC waits until Robotino finishes the task [140]. the Robotino asks for parameters of pallet delivery (M100. the station will be on Idle state [10]. Then the PLC sends “Task finished” message (M100. Then the PLC sends a “Task started” message (M100. The Robotino transports the pallet form the storage to the selected output slide [130]. The PLC updates the Robotino Storage buffer in MES (M100.4 MES mode of Robotino 2 In MES mode the Robotino 2 has only one task (Transportation of commissioned pallet from Robotino Storage to outline slide). After the answer is received.KG. and a pallet in the Robotino Storage. the PLC selects the next free output slide.

31) 2 150 1 © Festo Didactic GmbH & Co.KG. • prolog-factory . there is a pallet in the Robotino storage Empty: Wait MES request finished Answer received 100 155 Get parameters for delivery (M100.41) Send "Task finished" (M101.1) 110 160 Empty: Wait MES request finished Empty: Wait MES request finished Answer received Answer received There is a delivery task from storage Else 115 Select output slide 120 Send "Task started" (M100.10) 125 Empty: Wait MES request finished Answer received 130 Robotinio moves the pallett to out. slide 135 Empty: Wait until Robotino is busy Robotino is busy Error in Robotino communication 140 Empty: Wait until Robotino finished Robotino finished Error in Robotino communication 145 Update storage buffer in MES (M100. there is a free output slide.Process description 2 1 10 150 Station on Idle state MES mode is active.

• prolog-factory 151 . 9.KG. Even the load-capacity of the floor must be high enough for the system.9 Technology This chapter refers to the technology of the system. The size of the door openings and the entrance must be big enough for the measurements of the system. For better construction understanding of the station. is driven by 24 V-engines. The conveyor belt. the technical drawings should be a very helpful data.1 drawings Technical drawing © Festo Didactic GmbH & Co. which results in an average transport speed of about 9 m/min. with a width of 40 mm. The rooms must be checked for their technical datas before built up the station/system.

The palette can be moved from the robot by means of the reception aid at the center of the palette. some of which are also used in the field of MPS-Plus.2. • prolog-factory .KG. Pallet Work pieces 9.1 Pallet Responsible for the transport of 4 processed or unprocessed cylinders. Measurements: 164 x 164 mm Pallet 1BPW 152 © Festo Didactic GmbH & Co.Technology 9. On the bottom side there is the RFID Sensor.2 Modules in use The conveyor system is made up of a number of different function modules.

• prolog-factory 153 . black and silver work pieces are available.Technology 9. they distinguish in their color – red. Work pieces © Festo Didactic GmbH & Co.2 Work pieces There are 3 different work pieces.2.KG.

Technology 154 © Festo Didactic GmbH & Co. • prolog-factory .KG.

The filter and water separators require maintenance according to the instructions of the documentation of these components. to prevent contamination by rust or similar.1 Pneumatic supply The pressure in the supply line must not exceed 10 bar. The exact allocation of the valve terminal can be found in the pneumatic plan. Service unit © Festo Didactic GmbH & Co. A fine filter has to be installed.10 Pneumatic 10. The pressure regulators should be set in between 5 and 6 bar. • prolog-factory 155 . A stop cock is required for the supply of the installation.KG.

KG. • prolog-factory .Pneumatic 156 © Festo Didactic GmbH & Co.

To give you a better survey of the being lines used in the plant. which at first reacts to its respective station only. these are explained in the following. if a central ROOM EMERGENCY STOP switch is required. • prolog-factory 157 .11 Electrical system To operate the system it is required to connect all of the supply cables and communication lines included. If it is required for several devices to be in operation at the same time. © Festo Didactic GmbH & Co. The customer must ensure that the power supply is earthed correctly and is equipped with a fault current monitor.1 Power supply The devices are delivered together with the respective power supply plugs. Each station contains its own individual EMERGENCY STOP switch. 11. It has to be clarified in advance. provided that the permissible maximum rating is not exceeded. protectively contact covered. in case they require power supply. it is possible to connect these to a switchboard containing distribution board. The cables used to program the system are explained additionally.KG.

2 Controller The controller of the log area is located at the profile rack of the table.KG. Name Comment 1 BL20-GW-DPV1 Controller 2+3 BL20-2RFID-S Card for RFID sensors 4 24V Power Card for powers supply inputs 5-10 BL20-4DI-24VDC-P Cards for digital Inputs 11 24V Power Card for powers supply outputs 12-14 BL20-4DO-24VDC-0. • prolog-factory .Electrical system 11. No.5A-P Cards for digital outputs S7 controller transport system example 158 © Festo Didactic GmbH & Co.

the moduls from the profil plate and the z-axis are pluggable connected via I/O-terminals to the SM323 I/O-cards from the control.3 Wiring The wiring within the station and the wiring to the other stations are explained in the following.Electrical system 11. • prolog-factory Plug type IEEE 488 24 pins Inputs 8 Outputs 8 Current consumption Max.3. the I/O interface is standardized. So that a perfect communication can be ensured.1 I/O-Components The operating strip. The I/O terminal is at all work positions at the disposal. I/O-Terminal Technical data © Festo Didactic GmbH & Co. 11. 1A/PIN Power supply 24 VDC 159 .KG.

• prolog-factory .KG.Electrical system Allocation I/O.Terminal Clamp Bit Function Colour Clamp Bit Function Colour 01 0 Output White 13 0 Input Grey-pink 02 1 Output Brown 14 1 Input Red-blue 03 2 Output Green 15 2 Input White-green 04 3 Output Yellow 16 3 Input Brown-green 05 4 Output Grey 17 4 Input White-yellow 06 5 Output Pink 18 5 Input Yellow-brown 07 6 Output Blue 19 6 Input White-grey 08 7 Output Red 20 7 Input Grey-brown 24V Power supply Black 21 24V Power supply White-pink 09 10 11 12 160 22 0V Power supply Pink-brown 23 0V Power supply purple 24 0V Power supply White-blue © Festo Didactic GmbH & Co.