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CIROS®

Advanced
Mechatronics

Manual

572761 EN
01/2010

Order No.: 572761
Status: 01/2010
Authors: Christine Löffler
Graphics: Doris Schwarzenberger
Layout: 01/2010, Beatrice Huber, Julia Saßenscheidt

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, 2006-2010
Internet: www.festo-didactic.com
E-Mail: did@de.festo.com

The copying, distribution and utilisation of this document as well as the
communication of its contents to others without express authorisation
is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved, in particular the right to carry out patent, utility
model or ornamental design registration.

2

Contents

1. What will you learn from the manual? ____________________ 5

2. This is how you install CIROS® Advanced Mechatronics _____ 8
2.1 User-specific installation of default sample systems
and S7 programs used ________________________________ 8

3. The CIROS® Advanced Mechatronics system _____________ 11
3.1 Summary of CIROS® Advanced Mechatronics _____________ 11
3.2 A distributed system in CIROS® Advanced Mechatronics____ 15
3.3 Communication in distributed systems __________________ 17
3.4 The preassembled station models in
CIROS® Advanced Mechatronics _______________________ 19
3.5 Controlling a station with internal PLC __________________ 27
3.6 Controlling a station with external PLC __________________ 28
3.7 Functions for setting faults in a system__________________ 30
3.8 Functions for analysing a system ______________________ 31
3.9 Directory and file structure of
CIROS® Advanced Mechatronics _______________________ 33

4. Main control functions of CIROS® Advanced Mechatronics __ 38
4.1 Creating a new MPS® Standard system
from preassembled station models _____________________ 38
4.2 Creating an MPS® 500-FMS system
from preassembled station models _____________________ 58
4.3 Modifying an existing system _________________________ 78
4.4 Creating and monitoring communications links
in a system ________________________________________ 93
4.5 Simulating a system ________________________________ 120
4.6 Operating and monitoring a system ___________________ 124
4.7 Changing the view of a system _______________________ 145
4.8 The Inputs and Outputs windows _____________________ 149
4.9 The Manual Operation window _______________________ 157
4.10 Controlling a system using the internal S7 PLC __________ 183
4.11 Controlling a system station using
the external Soft PLC S7-PLCSIM ______________________ 199

© Festo Didactic GmbH & Co. KG „ 572761 3

Contents

4.12 Controlling a station of the system using
the external Soft PLC CoDeSys SP PLCWinNT ____________ 215
4.13 Controlling a station of the system using an external PLC __ 241
4.14 Setting faults in a system ____________________________ 259
4.15 Eliminating faults in a system ________________________ 267
4.16 Logging error elimination ____________________________ 272

5. These training contents can be taught using
CIROS® Advanced Mechatronics ______________________ 274
5.1 Training contents and training aims ___________________ 274
5.2 Target group ______________________________________ 277
5.3 Prior knowledge ___________________________________ 277
5.4 Example: Allocation of training aims to syllabi ___________ 278
5.5 The training concept of CIROS® Advanced Mechatronics ___ 284
5.6 Training scenarios for CIROS® Advanced Mechatronics ____ 286

6. This is how you create and operate a distributed
system in CIROS® Advanced Mechatronics ______________ 289
6.1 Training aims _____________________________________ 289
6.2 Support via CIROS® Advanced Mechatronics ____________ 290
6.3 Example: Configuration of a distributed system from
MPS® Standard stations and simulating production ______ 290

7. This is how you analyse information flow in
a distributed system________________________________ 318
7.1 Training aims _____________________________________ 319
7.2 Methods _________________________________________ 319
7.3 Support via CIROS® Advanced Mechatronics ____________ 321
7.4 Example: Analysing information flow in
a distributed MPS® Standard system __________________ 321

4 © Festo Didactic GmbH & Co. KG „ 572761

1. What will you learn from the manual?

What is CIROS® Advanced CIROS® Advanced Mechatronics is an application from the CIROS®
Mechatronics? Automation Suite.
CIROS® Advanced Mechatronics is a PC based graphic 3D simulation
system for distributed automation systems. These systems consist of
different, internetworked, intelligent stations. The distributed systems
represent automation processes of varying complexity.
In the documentation and software, these systems are also referred to
as process models or workcells.

CIROS® Advanced Mechatronics is a tool whereby you
define an automation process and configure the corresponding
system for the predefined stations,
familiarise yourself with the mode of operation of a system,
familiarise yourself with and plan the communication between the
networked stations of a distributed system,
practise PLC programming and testing of PLC programs with the help
of systems,
carry out systematic fault finding on a system.

The individual contents can be extended in complexity depending on
the trainees’ prior knowledge.

The simulated systems are also available as actual systems. With these
you can successfully apply and consolidate the knowledge gained on
the virtual automation systems using actual systems.
In addition to the ready-made process models, CIROS® Advanced
Mechatronics also offers you the option of simulating process models of
your own design. You can create and modify process models using
CIROS® Professional, which is a further application available from the
CIROS® Automation Suite.

© Festo Didactic GmbH & Co. KG „ 572761 5

1. What will you learn from the manual?

Target group The manual is intended for
Trainers and teachers
The manual provides them with ideas and suggestions as to how
CIROS® Advanced Mechatronics can be used in lessons and in
vocations and further training.
Trainees and students
For whom the information and instructions on how to operate
CIROS® Advanced Mechatronics are of particular interest.

Structure of the manual The manual is divided into the following subject areas:
Chapter 2 contains information and instructions regarding the
installation and licencing of CIROS® Advanced Mechatronics.
Chapters 3 and 4 describe the system and the main operational
functions of CIROS® Advanced Mechatronics.
Chapter 5 deals with the didactic aspects and lists the training
contents taught with CIROS® Advanced Mechatronics. It further
represents the training concept and the resulting possibilities for
use in lessons.
Chapters 6 and 7 describe actual problems in relation to the training
contents, methodological procedures towards solutions and
implementation in CIROS® Advanced Mechatronics.

Conventions Specific notation is used for texts and key combinations and key
sequences to help you find information more easily.

Notation Meaning

Bold This format is used for command names, menu names, dialog box names,
directory names and command options.

Key1+key2 A plus symbol (+) between the key names means that the keys quoted must
be pressed simultaneously.

Key1‟key2 A minus symbol (-) between the key names means that the keys quoted must
be pressed in sequence.

6 © Festo Didactic GmbH & Co. KG „ 572761

These include: Next and Back. should you have any queries during the installation or operation of CIROS® Advanced Mechatronics. CIROS® Advanced Mechatronics Assistant offers you direct access to some ready made sample systems and prepared exercises. A sample PLC program is included for each station. Search. The Adobe Acrobat Reader program is available free of charge and you can download this from the Internet address www. CIROS® Help contains detailed information regarding the functions and operation of CIROS® Advanced Mechatronics. The PLC program is created in STEP 7. What will you learn from the manual? Additional support Further descriptions and support is available via the online Help. © Festo Didactic GmbH & Co. The online Help consists of: CIROS® Help for operation and CIROS® Advanced Mechatronics Assistant. Our telephone hotline is available at any time. Select Home Page. KG „ 572761 7 . A Getting Started section is also integrated for a quick introduction to CIROS® Advanced Mechatronics. via extension registers such as Content. Moverover. An Adobe Acrobat Reader must be installed on your PC to enable you to view PDF documents.1. Show/Hide the Navigation bar or Set Options for Internet Connection. different CIROS® applications. The menu of the online Help provides functions that you are already familiar with from a standard Internet browser. Favourites. you also have the option of conveniently navigating through the information in CIROS® Advanced Mechatronics Help. CIROS® Help is a component part of the CIROS® Automation Suite and describes the functionality of various.de. Print Selected Topics.adobe. The CIROS® Advanced Mechatronics Assistant provides detailed functional descriptions and technical documentation regarding the individual stations. The functional scope of CIROS® Help is therefore greater than that required for CIROS® Advanced Mechatronics. Moreover.

a PLC program must be User-specific installation available for each station of the system in order to control the operation of default sample systems of the station. 2. You can of course also download the modified PLC programs to an external PLC. 8 © Festo Didactic GmbH & Co. KG „ 572761 . On completion of the installation. in which case the respective station of the system using an external PLC. please refer to the enclosed instructions. As soon as this is successfully completed you can start CIROS® Advanced Mechatronics.1 To be able to simulate a modelled system. If you wish to modify one or several sample PLC programs. It also includes the manuals in the form of PDF documents for the individual software packages. For further information regarding system requirements. then the PLC programs must be installed in an additional subdirectory specified by you. This is how you install CIROS® Advanced Mechatronics To install CIROS® Advanced Mechatronics you will need the CIROS® Automation Suite DVD-ROM. the prepared sample PLC program is automatically downloaded to the internal PLC and executed once simulation is started. If you are working with the default settings of CIROS® Advanced Mechatronics. where all the software packages of the CIROS® Automation Suite are ready for installation. installation and licencing. where you can effect your changes.2. you will need to execute the licencing. Each station is equipped with an internal PLC to execute and S7 programs used PLC programs. This enables you to simulate the sample systems provided and any newly created system straight away and without errors. A S7 simulator is used as internal PLC. You can then download the modified programs to the appropriate station of your system and execute these.

The model and associated PLC programs cannot be modified. CIROS® Advanced Mechatronics supports you in the user-specific installation of the sample systems and S7 programms. This ensures that the process model can be opened and correctly simulated at any time. This is how you install CIROS® Advanced Mechatronics By using this procedure. To do so. Reference models are sample systems which are filed in the program directory of CIROS® Advanced Mechatronics and are write protected. CIROS® Advanced Mechatronics differentiates between reference models und user models. © Festo Didactic GmbH & Co. open up CIROS® Advanced Mechatronics Assistant. KG „ 572761 9 . the default PLC programs used by CIROS® Advanced Mechatronics remain unchanged and can be downloaded again to the internal PLC of a station.2.

KG „ 572761 . This is how you install CIROS® Advanced Mechatronics User models.2. You can also copy the user models into a folder other than into the standard preset folder. You will find the information for this in CIROS® Advanced Mechatronics Assistant. are filed as standard in your personal folder under own files\CIROS\CIROS Advanced Mechatronics Samples. For the user modells created with the help of CIROS® Advanced Mechatronics Assistant the following directory structure is created: 10 © Festo Didactic GmbH & Co. if created and opened with the help of CIROS® Advanced Mechatronics Assistant. These are not write protected and you therefore can for example modify the appropriate PLC programs and replace these with your own. The program directory with the user models represents your individual working environment for CIROS® Advanced Mechatronics.

KG „ 572761 11 . The online CIROS® Advanced Mechatronics Help. An Online Help for EzOPC. program and simulate distributed systems of varying complexity. An online CIROS® Advanced Mechatronics Assistant. 3.1 CIROS® Advanced Mechatronics is a PC-based graphic 3D simulation Summary of CIROS® system which serves as an introduction to automation systems with Advanced Mechatronics distributed intelligence. The CIROS® Advanced Mechatronics system The following form part of CIROS® Advanced Mechatronics: The simulation software CIROS® Advanced Mechatronics. One station is characterised by the fact that it independently executes specific machine functions. A PDF document with information regarding the licencing and installation of a licence server. CIROS Advanced Mechatronics enables you to create. The communication software EzOPC.3. A distributed system consists of one or several stations. it is therefore an autonomous system part with its own PLC program. A manual in the form of a PDF document for the operation of CIROS® Advanced Mechatronics. © Festo Didactic GmbH & Co.

. KG „ 572761 . This simulation ensures for example that cylinders move and sensors are actuated. A simulator that simulates the behaviour of the system. 12 © Festo Didactic GmbH & Co. if required. exchanges information with other stations. with Control station functions Internal Internal Internal models S7 PLC S7 PLC S7 PLC OPC-Client EzOPC (OPC-Server) Easy S7-PLCSIM CoDeSys PLCWinNT Port External PLC Component parts of CIROS® Advanced Mechatronics The following is required in order to simulate the operation of a distributed system: A graphic process model of the distributed system. A PLC program and PLC for each station. The CIROS® Advanced Mechatronics system CIROS® Assistant CIROS® Help System consisting of station models Library Station 1 Station 2 Station 2 . which autonomously controls the operation of the station and..3.

whereby it is possibly to set typical faults in the system. The advantage of this is that you can familiarise yourself with. You can of course create new PLC programs. they need to exchange information. In the next step you can establish or change the communication links yourself and make the necessary adjustments in the PLC programs. If a system is now modelled from the prepared stations. which executes the PLC program once simulation is started. The CIROS® Advanced Mechatronics system Each station is stored in a library together with a sample PLC program. a cable break or failure of a complete. which generate a different process sequence. The cause of the fault must be found by means of systematic fault finding and eliminated. KG „ 572761 13 . In order to ensure that the stations of the system interact correctly. The PLC program defines a possible sequence of the station. operate and observe the process without having to create the PLC programs for the individual stations beforehand.3. The default communication links used between the stations are established automatically. A SIMATIC S7 simulator is used as internal PLC. Possible causes of malfunction are for example a mechanically misadjusted sensor. the corresponding PLC program is automatically downloaded to the internal PLC of the station. One particular additional function provided by CIROS® Advanced Mechatronics is the possibility of fault simulation. © Festo Didactic GmbH & Co. This facility enables you to simulate the operation of a system immediately after modelling.

You can create and modify process models using CIROS® Professional. KG „ 572761 . The soft PLC CoDeSys PLCWinNT. Note In addition to the ready-made process models. CIROS® Advanced Mechatronics also offers you the option of using process models of your own design.3. which is a further application available from the CIROS® Automation Suite. The following are possible as external PLC: Any actual PLC. The Soft-PLC SIMATIC S7-PLCSIM. 14 © Festo Didactic GmbH & Co. The CIROS® Advanced Mechatronics system The monitoring and analysing of processes and the elimination of faults is a focal point of CIROS® Advanced Mechatronics. The OPC server EzOPC communicates with any PLC via the EasyPort interface. A further focal point is the creation of your own PLC programs for individual stations. CIROS® Advanced Mechatronics requires the software program EzOPC for the link to an external PLC. These PLC programs are downloaded to an external PLC and CIROS® Advanced Mechatronics exchanges the input/output signals with the external PLC via the OPC interface.

KG „ 572761 15 . MPS® 500-FMS systems. Pick & Place station. Robot station. Sorting station. Mechatronics An "intelligent unit" consists of a station.for MPS® 500-FMS stations. Two types of system can be created from the stations listed above: MPS® Standard systems. an internal PLC and an optional robot program. The predefined sequence of the PLC controlled stations can of course be modified by the user. a predefined sequence with predefined communication interface. Distributing station. Quality assurance station. a PLC program.3. Storing station. Each station A distributed system in represents an "intelligent unit". The CIROS® Advanced Mechatronics system 3. Robot assembly station. Handling station Automated warehouse station. Separating station.2 Systems can be created from one or several stations. Pallet transport system with 6 working positions ‟ so-called docking positions . which independently executes specific CIROS® Advanced machine functions. All stations are prepared for your use: Processing station. Buffer station. © Festo Didactic GmbH & Co. Testing station. Fluidic Muscle Press station.

KG „ 572761 . The CIROS® Advanced Mechatronics system Example of an MPS® Standard system Example of an MPS® 500-FMS system 16 © Festo Didactic GmbH & Co.3.

In the case of MPS® Standard systems a station usually communicates with the preceding and successor station. How and with whom the stations communicate depends on their position in the material flow. the Communication in "intelligent units" of the system must exchange information. Note A system can also be configured of only one station.3 To ensure the correct sequence of the production process. The CIROS® Advanced Mechatronics system The stations are available from two libraries: The MPS® stations library. Through-beam senor emitters and receivers are used as StationLink sensors. they need to communicate with one another. only specific combinations are permissible when modelling a system. In MPS® systems these are the individual stations. KG „ 572761 17 . one bit is exchanged in each case. This enables you to teach all the training contents for which only one individual station is required. In the standard version. © Festo Didactic GmbH & Co. This type of coupling of stations is referred to as StationLink. MPS® 500-FMS systems include stock administration and assembly of short-stroke cylinders. the MPS® 500-FMS library. Information is exchanged via optical sensors. 3. MPS® systems perform different production processes: MPS® Standard systems perform the assembly of measuring instruments and short-stroke cylinders. Due to the technological functions of the individual stations and if using the prepared PLC programs. In other distributed systems words.3.

This type of communication is known as I/O connection. each station forming part of the transport system communicates with the transport system. Projection and representation of communication links 18 © Festo Didactic GmbH & Co. The CIROS® Advanced Mechatronics system With MPS® 500-FMS systems. If two stations are in use at one working position.3. the stations located at the working positions of the transport system use the optical sensors for information exchange. If changes are made in the communication link. such as the distributing and testing stations at the position for incoming goods. KG „ 572761 . you need to make sure that the PLC programs of the respective stations make available the communication information accordingly and conversely also evaluate it again. The part of communication conducted via I/O connection can be graphically projected and modified. Only in this way does the transport system know which stations are involved in the production process and in which working position these are. an information exchange therefore also takes place between these two stations. All stations of an MPS® 500-FMS system communicate via the coupling of PLC inputs and outputs. In addition.

Fluidic Muscle Press station This model is a simulation of the Fluidic Muscle Press station from Festo Didactic.4 The station models are realistic replications of existing stations. Advanced Mechatronics Station model Description Processing station This model is a simulation of the MPS® processing station from Festo Didactic. The CIROS® Advanced Mechatronics system 3. if required. a robot program. The preassembled station Apart from the graphic representation. KG „ 572761 19 . each station model comes with a models in CIROS® sample PLC program and.3. © Festo Didactic GmbH & Co. On this station workpiece inserts are to be pressed into the workpiece housings and the finished workpiece transported to the transfer position. processed and transferred to the neighbouring station. On this station workpieces are to be tested.

On this station workpiece are to be stocked up and taken out. deposited on a slide. KG „ 572761 .3. The workpieces can also be passed on to a neighbouring station. The CIROS® Advanced Mechatronics system Station model Description Handling station This model is a simulation of the MPS® handling station from Festo Didactic. On this station workpieces are to be removed from a mounting and. 20 © Festo Didactic GmbH & Co. Automated warehouse station This model is a simulation of the automated warehouse station of Festo Didactic. depending on the result of the material testing.

Depending on the position of the station within the material flow. On this station workpieces are to be placed onto workpiece housings and the complete workpiece is transported to the transfer station.3. workpieces are to be either stocked up or taken out. KG „ 572761 21 . © Festo Didactic GmbH & Co. Pick & Place station This model is a simulation of the Pick & Place station of Festo Didactic. The CIROS® Advanced Mechatronics system Station model Description Storing station This model is a simulation of the storing station of Festo Didactic.

22 © Festo Didactic GmbH & Co. The CIROS® Advanced Mechatronics system Station model Description Testing station This model is a simulation of the MPS® testing station from Festo Didactic. On this station the material condition of the workpieces is to be established and the workpiece height checked. buffered and separated.3. On this station workpieces are to be transported. Depending on the test result. the workpiece is to be ejected or transferred to the neighbouring station. Buffer station This model is a simulation of the MPS® testing station from Festo Didactic. KG „ 572761 .

The CIROS® Advanced Mechatronics system Station model Description Quality assurance station This model is a simulation of the MPS® quality assurance station from Festo Didactic. KG „ 572761 23 . Robot station This model is a simulation of the MPS® robot station from Festo Didactic. © Festo Didactic GmbH & Co. Depending on the result. workpieces are sorted into different magazines and passed on to the neighbouring station. On this station workpieces are to be sorted according to colour and the correct alignment of workpieces monitored.3. On this station the shape tolerance of workpieces is to be tested.

The CIROS® Advanced Mechatronics system Station model Description Robot assembly station This model is a simulation of the MPS® robot assembly station from Festo Didactic. On this station a model cylinder is to be assembled from a basic body. Sorting station This model is a simulation of the MPS® sorting station from Festo Didactic.3. KG „ 572761 . 24 © Festo Didactic GmbH & Co. On this station workpieces are to be sorted according to material and colour.

On this station the material flow is split The basic body for the cylinder is transferred to conveyor 1 and the housing for the measuring instrument is transported to conveyor 2 and transferred to the neighbouring station. On this station workpieces are to be transported to the individual station of an MPS® 500- FMS system. The CIROS® Advanced Mechatronics system Station model Description Transport system station This model is a simulation of the MPS® transport system station from Festo Didactic. KG „ 572761 25 . © Festo Didactic GmbH & Co.3. Separating station This model is a simulation of the MPS® separating station from Festo Didactic.

3. The CIROS® Advanced Mechatronics system Station model Description Distributing station This model is a simulation of the MPS® distributing station from Festo Didactic. KG „ 572761 . On this station workpieces are to be separated and passed on to the neighbouring station. 26 © Festo Didactic GmbH & Co.

The CIROS® Advanced Mechatronics system 3. KG „ 572761 27 . © Festo Didactic GmbH & Co. FCH. This enables you to familiarise yourself with the running of a system immediately after modelling in the simulation.5 Each station in CIROS® Advanced Mechatronics has an integrated Controlling a station with SIMATIC S7 simulator as internal PLC. When you start the simulation of a system. Detailed information regarding the functional scope of the internal PLC can be found on the CIROS® online Help. the internal PLC executes the sample PLC program forming part of the station. STL and GRAPH programs created in STEP 7. The S7 simulator can execute internal PLC LDR.3.

KG „ 572761 . You do not need any additional hardware components if you use the Soft-PLC S7-PLCSIM or CoDeSys SP PLCWinNT as external PLC. we recommend that you download the programs external PLC to an external PLC and execute them from this. The advantage of this is that you can use the PLC and the programming system of your choice. Station of a system PLC programming system STEP7 Soft PLC S7 PLCSIM Information exchange with configuration using the external Soft-PLC S7-PLCSIM 28 © Festo Didactic GmbH & Co. This includes the status display of PLC input/outputs and variables. the online display of the PLC program and also the read-out of machine statuses. the testing and diagnostic functions provided by the programming system are thereby available to you in the PLC program for fault finding.6 If you are creating and testing your own PLC programs for the individual Controlling a station with stations of a system. The CIROS® Advanced Mechatronics system 3. Also.3.

KG „ 572761 29 . Station of a system PLC programming system STEP7 EasyPort PLC Information exchange with configuration using an external hardware PLC © Festo Didactic GmbH & Co. The CIROS® Advanced Mechatronics system If you use a hardware PLC as external PLC. you will need EasyPort and the data cable for the exchange of input/output signals. conversely. the statuses of the sensors and actuators of the corresponding station are communicated to the external PLC.3. EasyPort transmits the input/output signals of the PLC to the OPC server EzOPC via the serial or USB interface of the PC. The OPC server passes on the data to the selected station during the system simulation and.

faults in a system A list of typical faults is available for each station. The trainees enter the suspected fault in the dialog box for error elimination. Select one or several faults from this list. the system then operates correctly. The entries in the dialog box for fault elimination are logged and can be viewed by trainers and teachers. KG „ 572761 .7 The dialog to set faults in a system is password protected. Access to Functions for setting this dialog is available solely to trainers and teachers. 30 © Festo Didactic GmbH & Co. The CIROS® Advanced Mechatronics system 3. If the fault has been correctly identified.3. The task for trainees is to identify and describe the fault occurring during system operation and to subsequently determine the cause of the fault.

you can operate and visually monitor the process.3. © Festo Didactic GmbH & Co. KG „ 572761 31 . The process is controlled via the pushbuttons and switches of the individual control consoles. you have numerous options to Functions for analysing a monitor and analyse the operation of a system. system As soon as system simulation is active and the PLC programs of the individual stations control the operation of the system. The CIROS® Advanced Mechatronics system 3.8 With CIROS® Advanced Mechatronics.

If compressed air is applied to a cylinder connection. A Manual Operation window provides an overview of all process statuses and process activities. The compressed air tubing itself is not simulated. The statuses of the PLC inputs/outputs are shown in separate windows. The CIROS® Advanced Mechatronics system LEDs on the sensors and valves indicate the electrical status of the process components. In the Manual Operation window you can also display the communication links between two selected stations. If a PLC program is not active during system simulation. whereby you can for example control the movement of a cylinder or the switching on or off of an electric motor. you can use the Manual Operation window to activate individual process activities. By setting stops. 32 © Festo Didactic GmbH & Co. LEDs on the PLC inputs and outputs on the control console indicate the status of the communication realised via these inputs and outputs.3. then use the Manual Operation window as tool for control. If you want to execute the sequence step-by-step. then the connection is highlighted in blue. you can stop the process at defined points. KG „ 572761 .

of CIROS® Advanced Mechatronics © Festo Didactic GmbH & Co.9 Here you obtain information about the directory and file structure of Directory and file CIROS® Advanced Mechatronics. The CIROS® Advanced Mechatronics system 3.3. You want to modify the sample PLC programs for the individual stations of a system. Advanced Mechatronics You want to make available the model of a system to other users. Directory structure The following directory structure is created if you install CIROS® following the installation Advanced Mechatronics with the default settings offered. structure of CIROS® This information is useful if. KG „ 572761 33 .

. MB4 S7 313c___1 PLC programs for MPS 500-FMS stations FMS50__1 PLC program for MPS 500-FMS transport system MPSC_V22 PLC programs for MPS Standard stations Store PLC program for MPS 500-FMS automated warehouse station Samples ... The CIROS® Advanced Mechatronics system Programs .. KG „ 572761 . testing and sorting stations (one bit communication) Programs PLC and robot programs for all MPS stations 34 © Festo Didactic GmbH & Co. ciros advanced mechatronics. ..en bin FD_PLC_ADV . Models MPS500-FMS51 MPS 501-FMS system Model Workcell for MPS 501-MPS system Programs PLC program for MPS 501-FMS system MPS500-FMS57 MPS 507-FMS system MPS System MPS Standard system with separating with separating station Multi-Bit-IO MPS VE-PR MPS Standard system with distributing and testing stations (multi bit communication) Model Programs One-Bit-IO MPS VE-PR MPS Standard system with distributing and testing stations (one bit communication) MPS VE-PR-SO MPS Standard system with distributing. ..3. .

It is however difficult to allocate bmp files to individual systems. Moreover the list of bmp files is more extensive. then files with corresponding names are also available for these systems. For easy identification. CIROS® Advanced Mechatronics Assistant helps you copy models and example PLC programs. The CIROS® Advanced Mechatronics system The S7 project with the sample PLC programs for the individual stations is stored in the directory S7. where you carry out your modifications. You can then download the modified programs to the internal PLC of the appropriate station and execute it. With this procedure. All files which are part of the graphic representation of the system are filed in the user-defined subdirectory. the default PLC programs used by CIROS® Advanced Mechatronics remain unchanged and can be reloaded again to the internal PLC of a station at any time. If you want to modify one or several of the sample PLC programs or of the process models. KG „ 572761 35 . Project structure for the The example of a system is used to show what files form part of a modelled systems modelled system and what information is stored in these files. you need to copy the directory Samples in another subdirectory defined by you. © Festo Didactic GmbH & Co. A system is also known as a process model or workcell. These original PLC programs must not be modified! The same applies to S7 programs and process models in the folder Samples. If additional CIROS® Advanced Mechatronics systems are also stored in the subdirectory viewed. copied models are called user models and the original models are called reference models.3.

Example. The file *. It also contains a reference to the location and name of PLC programs to be executed after simulation of the internal PLCs of the stations is started. These PLC programs control the running of individual system stations.3. fault settings.prot Log of fault localisation: The file is read in teacher mode and displayed in the fault log window. 36 © Festo Didactic GmbH & Co. Example. which are executed either via an internal or external PLC. KG „ 572761 . If this file exists in the process model directory. Files for a process model A system also includes PLC programs. then the fault settings filed in the ini-file are used. Example.htm Exporting of fault log: Modifications in the fault log are automatically exported into these files.mcf Fault settings: This file contains all the settings regarding the activation. The bitmap files required are dependent on which stations are used in the system.bmp Various bitmap files required for the graphic display of the system.ini Initialisation of the process model: The file contains all user-specific settings for the process model such as window configuration. duration and type of a fault.ini includes a reference to the memory location of the PLC programs. Example. etc. it overwrites the settings in the ini-file. start.mod Process model of a system named Example.xls These files can then for example be viewed via Microsoft Internet Explorer or Example. The CIROS® Advanced Mechatronics system File Description Example.txt Microsoft Excel. Example. If it does not exist. *.

the best way to proceed is as follows: Select all the files forming part of the system. the reference in the ini file to the memory location of the PLC programs is automatically corrected. KG „ 572761 37 . start CIROS® Advanced Mechatronics on the new PC and download the copied process model. If this is not the case. make sure that the sample PLC programs on the new PC are stored in the same path as on your PC.3. The PLC program must be downloaded to the corresponding system stations on the new PC. These are all the files. then these programs must also be available on the new PC. Copy the selected file to a subdirectory of the desired PC. By downloading the PLC programs. The subdirectory on the target PC must have the same name and the same path as on your PC. Then download the desired PLC program from the relevant directory on the new PC to the internal PLC of the individual system stations. If the station is operated using the sample PLC programs. © Festo Didactic GmbH & Co. If one or several stations of the system are controlled via your own created PLC programs. The CIROS® Advanced Mechatronics system You need to keep this in mind if you want to copy a system you have modelled yourself to another PC and simulate from there. If you want to copy the process model of a system. The system can now be simulated. which have the name of the respective system and all the bitmap files.

Storing station. This library contains the station models for the following: Processing station. preassembled station MPS® 500-FMS library. KG „ 572761 . appropriate key combinations or the context-sensitive menu with the right mouse button. 4. then use the models from the MPS® stations library. models If you want to model a new MPS® Standard system. "Old" and "new" standards differ with regard to the designations of valve coils. the library has been extended with the addition of new station models. Various options to activate commands are available via MS Windows programs.4. Detailed information regarding the use of all the options of CIROS® Advanced Mechatronics can be found in the online Help for this software package.1 The stations models for the configuration of a system are available in Creating a new MPS® two libraries: Standard system from MPS® stations library. Fluidic Muscle Press station. Pick & Place station. Robot station. Note To enable you to create a wide range of different system. You can and should of course use the symbols bar. Main control functions of CIROS® Advanced Mechatronics This chapter describes the main control functions of CIROS® Advanced Mechatronics. In this description. Handling station. The new standards regarding circuit diagram design are taken into consideration in the PLC programs and circuit diagrams. commands are triggered via entries in the menu bar. Buffer station. 38 © Festo Didactic GmbH & Co. pushbuttons and switches as well as indicator lights. Testing station.

The automatic alignment ensures that the StationLink sensors of neighbouring stations are also correctly positioned. Note A system can also be configured of just one station. The alignment and connection of models is effected in a simple way via specified coupling points on the models. The StationLink sensors are optical sensors which transmit the communication signal. Sorting station. © Festo Didactic GmbH & Co. The possible combinations.e. Main control functions of CIROS® Advanced Mechatronics Robot assembly station. only certain combinations are permissible when modelling a system. i. KG „ 572761 39 . Due to the technological functions of the individual stations. Separating station Distributing station. Station models for an MPS® Standard system are arranged directly next to one another.4. subsequent stations. are indicated with grey shading. whereby you can teach all the training contents in CIROS® Advanced Mechatronics for which only a single station is required.

KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics This is how you Distributint – adjusted for successor station Handling – adjusted Handling –adjusted combine your MPS® Standard for termination Distributing – stations Pick & Place Processing for Testing Standard Testing Buffer Distributing ‟ Standard Distributing ‟ adjusted for testing Testing Processing Handling ‟ adjusted for successor station Handling ‟ adjusted for termination Buffer Pick & Place Fluidic Muscle Press Separating Storing ‟ Stock up Storing ‟ Take out Robot Robot assembly Sorting Permissible station combinations for MPS® Standard systems 40 © Festo Didactic GmbH & Co.4.

Main control functions of CIROS® Advanced Mechatronics This is how you Fluidic Muscle Press combine your Storing – Stock up Storing – Take out MPS® Standard Robot assembly stations Separating Sorting Robot Distributing ‟ Standard Distributing ‟ adjusted for testing Testing Processing Handling ‟ adjusted for successor station Handling ‟ adjusted for termination Buffer Pick & Place Fluidic Muscle Press Separating Storing ‟ Stock up Storing ‟ Take out Robot Robot assembly Sorting Permisible station combinations for MPS® Standard systems © Festo Didactic GmbH & Co. KG „ 572761 41 .4.

Depending on the combinations in which the stations are used. The sensors which determine and detect the swivel angle on the transfer module must be correspondingly set. then you use the variant Storing Station ‟ Stock up. Each sequence is realised via a separate PLC program. The robot station can also deposit workpieces at two different positions: Internally on the station or externally on the transfer position of the successor station. In this case you will require the variant handling station – adjusted for termination. The lower transfer position is required for the testing station. KG „ 572761 . Two sequences are available for the storing station: The station can stock up or take our workpieces. This station can therefore both be used in the middle of or as a last station in a production system. The robot program automatically detects whether or not a neighbouring station follows and adapts the robot movement accordingly. If the station is at the beginning of the material flow it thus forms the first station of a system ‟ consequently workpieces are taken out. The handling station can deposit workpieces at two different positions: Internally on the station or externally at the transfer position of the sucessor station. The distributing station can deposit workpieces at two different transfer positions. then the workpieces are deposited on the station itself. The sensor which determines the transfer position of the axis must be correspondingly positioned. If the handling station forms the end of a system. handling and storing stations are available in two variants. individual sensors and stops are differently positioned and adjusted. If the storing station forms the end of a system. This variant of the handling station is referred to as handling station – adjusted for successor station. If there is a successor station. In this case you will require the variant Storing Station ‟ Take out.4. 42 © Festo Didactic GmbH & Co. The distributing station variants are therefore correspondingly designated with distributing station – adjusted for testing station and distributing station – standard design. Main control functions of CIROS® Advanced Mechatronics The distributing. the workpieces are deposited on the transfer position of the successor station. all other stations operate using the higher transfer position.

1.4. © Festo Didactic GmbH & Co. A combination consisting of the distributing. testing and sorting stations is to be configured. both the activity window and the help window are opened. The modelling of an MPS® Standard system is explained with the help of an example. KG „ 572761 43 . Start CIROS® Advanced Mechatronics. When CIROS® Advanced Mechatronics is started. This is how you create an MPS® Standard system An MPS® Standard system consisting of the distributing. testing and sorting stations is to be created. Main control functions of CIROS® Advanced Mechatronics The operation of the system with the prepared PLC programs can only be simulated fault-free if a system is correctly assembled.

3. In addition. KG „ 572761 . Then click onto Save. Click onto MPS® System. If you do not require the information of the Assistant when starting CIROS® Advanced Mechatronics.4. Select a directory as memory location for the new system and enter the file name. Under file type. The window Create MPS® System is now displayed. deactivate the entry Open Automatically of the assistant in the Help menu. Activate the command New in the File menu. 44 © Festo Didactic GmbH & Co.mod). 2. select CIROS® Workcells (*. This is where a functional description and technical documentation regarding the model are available. you can download a few prepared sample systems directly from the Assistant. Main control functions of CIROS® Advanced Mechatronics Note In CIROS® Advanced Mechatronics Assistant open the folder which contains the required process model.

4. a number of the following settings are automatically effected in CIROS® Advanced Mechatronics: ‟ The change into Edit Mode is effected. Main control functions of CIROS® Advanced Mechatronics 4. The model of a blank system is displayed. A brief description of the model selected is displayed when you click onto Details in the Model Libraries window. ‟ The Model Libraries window is open. By creating a new system. KG „ 572761 45 . 5. ‟ The view selected is Top View. ‟ A table with the possible workpieces is made available. Detailed information regarding the models in the library is available on the online Help in the chapter CIROS® Advanced Mechatronics. © Festo Didactic GmbH & Co. You start Help by activating the command Examples and models of CIROS® Advanced Mechatronics in the menu Help.

Main control functions of CIROS® Advanced Mechatronics 6. The system now consists of the distributing station – adjusted for testing station model. The distributing station is available in two variants. A preview then displays the model. First add the distributing station model. Alternatively. KG „ 572761 . 46 © Festo Didactic GmbH & Co. Now click onto the Add button. Since the testing station follows the distributing station in the sample system. The distributing station is shown in green as it is still highlighted. add a model by double clicking on the relevant model corresponding model entry. Moreover the distributing station is connected automatically to the workpiece table. select the entry Distributing Station – Adjusted for Testing Station under MPS® Stations. since it has been added as the first station.4.

A coupling point is shown on side of the station. Click outside of the station to cancel the highlighting.4. which indicates that the distributing station can be connected to a further station at this point. KG „ 572761 47 . Main control functions of CIROS® Advanced Mechatronics 7. © Festo Didactic GmbH & Co.

4. you can change this using the commands in the View menu. Main control functions of CIROS® Advanced Mechatronics 8. 48 © Festo Didactic GmbH & Co. KG „ 572761 . If the representation of the station is too small.

© Festo Didactic GmbH & Co. KG „ 572761 49 . Now add the testing station as an additional station. Make sure that the Edit Mode is selected. Main control functions of CIROS® Advanced Mechatronics 9.4. You can establish this by the check mark next to the Edit Mode command in the Modeling menu.

by highlighting the testing station and. In order to ensure that the operating and transfer points coincide during the production run of the system. but are not yet connected. the station models must be appropriately aligned and connected. moving the mouse pointer to the desired position. Main control functions of CIROS® Advanced Mechatronics 10. by holding down the left mouse button. 50 © Festo Didactic GmbH & Co. The two models are next to one another.4. Move the newly added testing station. 11. KG „ 572761 . All stations are added at the same position in the workspace.

KG „ 572761 51 .4. grey shaded coupling point of the testing station. Now align the testing station model with the distributing station model. click onto the lower. Hold down the left mouse button and drag the coupling point to the coupling point of the distributing station. © Festo Didactic GmbH & Co. The testing station is now connected to the distributing station. To do so. Main control functions of CIROS® Advanced Mechatronics 12.

Add the sorting station as the last station. KG „ 572761 . This station is also shown at the predefined position in the activity window.4. Main control functions of CIROS® Advanced Mechatronics 13. 52 © Festo Didactic GmbH & Co.

4. still highlighted station and move it up next to the testing station. KG „ 572761 53 . © Festo Didactic GmbH & Co. Click onto the newly added. Main control functions of CIROS® Advanced Mechatronics 14.

4. 16. The system is configured. The highlighting of the model is cancelled as soon as you click outside of the station model. To do so. Main control functions of CIROS® Advanced Mechatronics 15. realised via optical sensors. KG „ 572761 . Hold down the left mouse button and drag the coupling point to the free coupling point of the testing station. click onto the grey shaded coupling point of the sorting station. are automatically established via the correct positioning and connecting of the stations. The communication links. 54 © Festo Didactic GmbH & Co. Connect the sorting station model with the upper free coupling point of the testing station model.

Note It is not absolutely necessary to connect the workpiece table to a station.4. Main control functions of CIROS® Advanced Mechatronics Exit the edit mode as soon as your system is configured. Change to the view mode to obtain a realistic 3D representation of the system. KG „ 572761 55 . You can position the workpiece table at any point within the workspace. © Festo Didactic GmbH & Co.

Main control functions of CIROS® Advanced Mechatronics This is how you change to the view mode 1. The check mark next to the Edit Mode is removed. 2. A 3D representation of your system is now displayed. KG „ 572761 .4. A top view is also shown. 3. 56 © Festo Didactic GmbH & Co. Close the Model Libraries window and select a perspective view of the system. Deactivate the Edit Mode command in the Modeling menu by clicking onto the Edit Mode command.

KG „ 572761 57 . rotate or zoom to obtain an appropriate view of your system. You can now simulate system production right away. The system is correctly configured and connected.4. To obtain a perspective view of the 3D model. Main control functions of CIROS® Advanced Mechatronics 4. select for example the command Standard Views/Default Settings in the View menu. With the commands under View you can move. © Festo Didactic GmbH & Co.

2 The station models to configure a system are available in two libraries: Creating an MPS® 500. KG „ 572761 . 58 © Festo Didactic GmbH & Co. preassembled station models If you want to model an MPS® 500-FMS system. 4. a Save prompt will be displayed when you close the process model. The possible configuration levels of an MPS® 500-FMS system are based on the full configuration of the MPS® 500-FMS system. MPS® Stations library. then use the station models from the MPS® 500-FMS library.4. where all six working positions on the transport system are occupied by a station or a combination of stations. answer the prompt with Yes or answer with No if you want to discard the changes. Main control functions of CIROS® Advanced Mechatronics Note Once you have created or modified a system. FMS system from MPS® 500-FMS library. If you want to save the changes.

© Festo Didactic GmbH & Co. KG „ 572761 59 . Station combination consisting of handling and processing stations. Station combination consisting of distributing and testing stations. Main control functions of CIROS® Advanced Mechatronics Product output Stock Assembly S HL RM Small parts store Presorting HH P H VI V B Product input Processing Quality assurance V: Distributing station P: Testing station HL: Automated warehouse station H: Handling station B: Processing station HH: Handling station VI: Quality assurance station RM: Robot assembly station S: Sorting station Full configuration of an MPS® 500-FMS system The following form part of a full configuration of an MPS® 500-FMS system: Pallet transport system station with 6 working positions for MPS® 500-FMS stations. Quality assurance station.4.

the station models are aligned with the transport system model and connected to it. the handling and processing stations combination at the position for processing and the handling and sorting stations in the form of product output. The sample system consists of a transport system. Station combination consisting of handling and sorting stations. Automated warehouse station. The following rules apply to create MPS® 500-FMS systems in different configuration stages: Only the listed six stations or station combinations can be positioned on the transport system.4. The connection or coupling points correspond to the stopper positions of the transport system. In the case of MPS® 500-FMS systems. Main control functions of CIROS® Advanced Mechatronics Robot assembly station. 60 © Festo Didactic GmbH & Co. the default communication links used are also simultaneously established. For each station or station combination. the distributing and testing stations in the form of product input. The position can be seen from the full configuration of an MPS® 500-FMS system. The modelling of an MPS® 500-FMS system is shown using a simple example. whereby individual stations or station combinations and their associated production steps are omitted. As a result of establishing the connections. KG „ 572761 . Example: The smallest MPS® 500-FMS system consists of the transport system station. The operation of the system can only be simulated error-free if a system is correctly configured. there is exactly one permissible working position in the transport system. Individual "positions" on the conveyor can remain unoccupied. the distributing and testing stations combination for product input and the handling and processing stations combination for product output. The positioning and alignment of the models is effected simply via the specified coupling points on the models.

Note In CIROS® Advanced Mechatronics Assistant open the folder which contains the required process model. KG „ 572761 61 . © Festo Didactic GmbH & Co. This is where a functional description and technical documentation regarding the model are available. Start CIROS® Advanced Mechatronics. Main control functions of CIROS® Advanced Mechatronics This is how you create an MPS® 500-FMS system 1. You can also download some prepared sample systems directly from the Assistant. If you do not need the information of the Assistant when starting CIROS® Advanced Mechatronics. then deactivate the entry for automatically opening the Assistant in the Help menu.4. When CIROS® Advanced Mechatronics is started both the activity window and the Help window are displayed.

mod). KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics 2. select CIROS® Workcells (*. Then click onto the Save button. 62 © Festo Didactic GmbH & Co. Activate the New command in the File menu. 3. The Create MPS® System window is now displayed. Enter the file name. Under file type. Select a directory to store the new system.4. Click onto MPS® System.

Main control functions of CIROS® Advanced Mechatronics 4. Detailed information regarding the models in the library is available on the online help in the chapter CIROS® Advanced Mechatronics.4. © Festo Didactic GmbH & Co. The model of a blank system is now displayed. Help is started by activating the command Examples and Models of CIROS® Advanced Mechatronics in the Help menu. some settings in CIROS® Advanced Mechatronics are automatically effected such as: ‟ Changing into the Edit mode. 5. ‟ The view selected is Top View. By creating a new system. A short description of the selected model is displayed if you click onto Details in the Model Libraries window. KG „ 572761 63 . ‟ The window Model Libraries is open. ‟ A table with possible workpieces is made available.

Now click onto the Add button. Alternatively. Main control functions of CIROS® Advanced Mechatronics 6. which is shown in green as it is still highlighted. The system now consists of the model of the transport system. First. insert the transport system model from the MPS® 500-FMS library by clicking onto Transport System. 64 © Festo Didactic GmbH & Co. you can add a model by clicking onto the corresponding model entry. A preview then displays the model. KG „ 572761 .4.

Click outside of the model to cancel the highlighting.4. These indicate that the transport system model can be connected with additional models at these points. © Festo Didactic GmbH & Co. KG „ 572761 65 . Three coupling points are shown on each of the longitudinal sides of the transport system model. Main control functions of CIROS® Advanced Mechatronics 7.

4. 66 © Festo Didactic GmbH & Co. KG „ 572761 . To do so. Move the transport system model into the centre of the workspace. highlight the model via a mouse click. Then drag the mouse pointer to the desired position by holding the left mouse button down. Main control functions of CIROS® Advanced Mechatronics 8.

KG „ 572761 67 . Now add the station combination for product input as a further model by double clicking onto Product Input. Main control functions of CIROS® Advanced Mechatronics 9. © Festo Didactic GmbH & Co.4.

The operating position for product input is at the bottom left of the transport system. To ensure that the operating and transfer points coincide during the production run of the system. 68 © Festo Didactic GmbH & Co. but are not yet connected. Main control functions of CIROS® Advanced Mechatronics 10. the models must be appropriately aligned and connected. The two models are next to one another.4. All stations are added at the same position in the workspace. KG „ 572761 . 11. Move the newly added product input station combination.

© Festo Didactic GmbH & Co. Main control functions of CIROS® Advanced Mechatronics 12. The station combination for product input is now connected to the transport system. KG „ 572761 69 . Now align the model for product input with the transport system model by clicking onto the grey shaded connecting point of the stations for product input. Hold down the left mouse button and drag the connecting point onto the connecting point of the transport system.4.

Next enter the station combination for the processing sequence by double clicking onto Processing in the MPS® 500-FMS library. Main control functions of CIROS® Advanced Mechatronics 13.4. KG „ 572761 . 70 © Festo Didactic GmbH & Co. This station combination is also shown at the predefined position in the activity window.

KG „ 572761 71 . Main control functions of CIROS® Advanced Mechatronics 14. Connect the newly added. By holding down the left mouse button drag the coupling point to the lower. © Festo Didactic GmbH & Co. middle coupling point of the transport system model.4. still highlighted model to the lower middle connecting point of the transport system model by clicking onto the grey shaded coupling point of the highlighted processing model.

Finally. add the model for product output. 72 © Festo Didactic GmbH & Co. Again. this model is shown at the predefined position in the activity window. KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics 15.4.

4. The operating position for product output is at the top left of the transport system. Move the newly added product output station combination. KG „ 572761 73 . Main control functions of CIROS® Advanced Mechatronics 16. © Festo Didactic GmbH & Co.

The default communication links used have been automatically established during modelling of the system. Main control functions of CIROS® Advanced Mechatronics 17.4. Now exit the Edit Mode and change to the View Mode to obtain a realistic 3D representation of the system. 19. 18. 74 © Festo Didactic GmbH & Co. Connect the product output model to the top left connecting point of the transport system. The system is created. KG „ 572761 . The highlighting of the model is cancelled as soon as you click outside of the station model.

KG „ 572761 75 . Main control functions of CIROS® Advanced Mechatronics This is how you change into the view mode 1. 2. Close the Model Libraries window. This will give you more space for the system representation.4. Deactivate the Edit Mode command in the Modeling menu by clicking onto the Edit Mode command. © Festo Didactic GmbH & Co. The check mark next to Edit Mode is removed. 3. A 3D display of your system is now displayed which also includes a top view.

rotate and zoom to obtain an appropriate view of your system. 76 © Festo Didactic GmbH & Co. KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics 4. With the commands under View you can move. select for example the Standard Views/Default Settings command in the View menu.4. To obtain a perspective view of the 3D model.

© Festo Didactic GmbH & Co. Activate the Edit Mode command in the Modeling menu and move the workpiece table to the desired position. The system is created and correctly connected. Main control functions of CIROS® Advanced Mechatronics 5. KG „ 572761 77 . You can now simulate system product straight away. The workpiece table can be positioned at a different point within your workspace at any time. Deactivate the Edit Mode command in the Modeling menu and generate an appropriate view of the system.4.

4. Main control functions of CIROS® Advanced Mechatronics

Note If you have newly created or modified the process model of a system, a
save prompt will be displayed when you close the process model.
If you want to save the changes, then answer the prompt with Yes, or
answer the prompt with No, if you want to discard the changes.

4.3 You can modify the model of a system and for example add further
Modifying an existing stations. How you proceed for this and what you need to observe
system depends on what communication links are to be used within the system.
In MPS® Standard systems, optical sensors are used as standard to
effect communication.
If the stations of an MPS® Standard system are correctly positioned
and connected, using the connecting points, then the
communication links are automatically established by means of this
process.
If you change an MPS® Standard system for which you have realised
multi-bit communication via I/O connection, then the
communication links must be re-established.
If you only use the default communication links prepared and want
to establish these, then activate the command Create
Communication Links in the Modeling menu.
All other communication links are to be established in the Manual
Operation window.
Multi-bit communication via I/O connection is available as standard
in MPS® 500-FMS systems.
When modelling, or also modifying such a system, the
communication links are set up automatically.
However, if you modify an MPS® 500-FMS system where you are not
using the prepared default communication links, you need to set up
the communication links yourself after modelling. User-defined
communication links are set-up in the Manual Operation window.

78 © Festo Didactic GmbH & Co. KG „ 572761

4. Main control functions of CIROS® Advanced Mechatronics

This is how you modify an already created system

1. Start CIROS® Advanced Mechatronics.
2. Download the desired system by activating the Open command in
the file menu.
3. The Open File window is now displayed.
Workcell (*.MOD) must be set as file type. Change into the directory
in which the process model of the system is stored. Select the
desired file and click onto the Open button.

4. View mode is set as standard. To change the system, change into
edit mode by activating the Edit Mode command in the Modeling
menu.

© Festo Didactic GmbH & Co. KG „ 572761 79

4. Main control functions of CIROS® Advanced Mechatronics

5. If you want to display information regarding the individual stations
of the system, you need to highlight the respective station via a
mouse click. Highlighted stations are shown in colour.

80 © Festo Didactic GmbH & Co. KG „ 572761

4. Main control functions of CIROS® Advanced Mechatronics

6. Open the context-sensitive menu via the right mouse button.
Activate the Properties command.
The Object Properties window is now open. The name indicates that
the highlighted station is a testing station.
Close the window when you have obtained all the necessary
information.

Note You will need the Object Properties function if you use a station in a
system several times and wish to identify the individual stations. You
identify a station by its name.
Example: If you are using the buffer station twice in your system, the
name of the station added first is Buffer and the name of the
subsequently added buffer station is Buffer_1.

© Festo Didactic GmbH & Co. KG „ 572761 81

4. Main control functions of CIROS® Advanced Mechatronics

7. If you now wish to add another station to your system, change to the
top view representation in View by activating the Standard
Views/Top View command in the View menu.

82 © Festo Didactic GmbH & Co. KG „ 572761

4. Main control functions of CIROS® Advanced Mechatronics

8. Select an appropriate representation of the system via zooming,
moving or rotating the system.

9. Make sure that edit mode is selected. You can establish this by the
check mark next to the command Edit Mode in the Modeling menu.
10. Now open the model libraries by activating the Model Libraries
command in the Modeling menu.
11. In the case of the sample system, this is an MPS® Standard system.
For modifications to the system, you will need the stations of the
MPS® Stations library. Open the library by clicking onto the +
symbol in front of MPS® Stations library.

© Festo Didactic GmbH & Co. KG „ 572761 83

Main control functions of CIROS® Advanced Mechatronics 12. KG „ 572761 . 84 © Festo Didactic GmbH & Co. Carry out your modifications to the system.4. If you want to expand the system by adding assembly functions. then add for example the Pick & Place and Fluidic Muscle Press stations between the sorting and testing stations.

© Festo Didactic GmbH & Co. Main control functions of CIROS® Advanced Mechatronics 13.4. KG „ 572761 85 . To add the desired stations. highlight the sorting station and move it up.

86 © Festo Didactic GmbH & Co. KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics 14.4. Now insert the Pick & Place station by double clicking the library entry Pick & Place Station.

© Festo Didactic GmbH & Co. Position the added station next to the testing station by clicking onto the highlighted Pick & Place station and move the mouse pointer to the desired position by holding down the left mouse button.4. KG „ 572761 87 . Main control functions of CIROS® Advanced Mechatronics 15.

Drag the coupling point to the coupling point of the testing station by holding down the left mouse button. 88 © Festo Didactic GmbH & Co.4. grey shaded coupling point of the Pick & Place station. KG „ 572761 . Connect the new Pick & Place station to the testing station by clicking onto the bottom. The testing and Pick & Place stations are now interconnected. Main control functions of CIROS® Advanced Mechatronics 16.

© Festo Didactic GmbH & Co. Connect this station to the Pick & Place station. KG „ 572761 89 . Use the same method to add the Fluidic Muscle Press station. Main control functions of CIROS® Advanced Mechatronics 17.4.

realised via the optical StationLink sensors. are automatically set up via the correct positioning and connection of the stations. Then drag the coupling point of this station to the unoccupied coupling point of the Fluidic Muscle Press station whilst holding the left mouse button. The changes to the system are completed. connect the sorting station to the Fluidic Muscle Press station. Finally. 19. Main control functions of CIROS® Advanced Mechatronics 18. KG „ 572761 . The communication links. Close the library and change to the view mode to obtain a realistic 3D display of the system.4. 90 © Festo Didactic GmbH & Co. To do so. highlight the sorting station.

Main control functions of CIROS® Advanced Mechatronics 20.4. Deactivate edit mode in the Modeling menu by clicking onto the Edit Mode command. The check mark next to Edit Mode disappears. KG „ 572761 91 . © Festo Didactic GmbH & Co.

Main control functions of CIROS® Advanced Mechatronics 21. 22. rotate or zoom to obtain an appropriate view of your system. To obtain a perspective view of the 3D model. select for example the Standard Views/Default Settings command in the View menu. Select the Save as command if you want to save the system under a new name. 92 © Festo Didactic GmbH & Co.4. Save the modified status of the system by activating Save in the File menu if you want to keep the current file name. KG „ 572761 . By using the commands under View you can move.

4. You will find the technical documentation and information regarding the sample PLC program in the CIROS® Advanced Mechatronics Assistant. communication takes place in the form of 1-bit connection via optical sensors as standard. communications links in a system MPS® Standard systems In an MPS® Standard systems. If you have expanded the 1-bit communication in a MPS® Standard system to multi-bit communication via I/O connection. the optical sensors are also correctly positioned to transmit communication signals. can the information exchange between the system stations take place during simulation. the communication exchange is realised differently Creating and monitoring between the individual stations of a system. activate the Examples and Models of CIROS® Advanced Mechatronics command in the Help menu. Open the context-sensitive menu via the right mouse button. then you will need to create the additionally required communication links in the virtual system. As soon as the stations of a system are correctly positioned and connected with the help of the coupling points. whereby you proceed as follows: Highlight the respective station. where you activate the Remove command. © Festo Didactic GmbH & Co. The prerequisites for error-free transmission of communication information are therefore in place. 4. Only if these communication links have been set up. The station highlighted is removed. To open the CIROS® Advanced Mechatronics Assistant. The absolute addresses of the PLC inputs and outputs of a station connected to the optical sensors can be found in the allocation list of the sample PLC program. Main control functions of CIROS® Advanced Mechatronics Note In the same way as you can expand a system by adding new stations you can also remove existing stations of a system.4 In MPS® system. KG „ 572761 93 .

Conversely. Main control functions of CIROS® Advanced Mechatronics Different PLC inputs and outputs are available for the transmission of communication information. You can see all I/O communication links set up for an MPS® system in the Manual Operation window. KG „ 572761 . testing and sorting stations. To enable you to work with a networked system promptly. The prepared default communication links are shown as examples for an MPS® Standard system. the connections between the stations are set up along the above lines. You can establish these at the click of a button (Modeling/I/O Configuration/Create Communication Links). whereby specific PLC outputs of a station are connected to specific PLC inputs of neighbouring stations. 94 © Festo Didactic GmbH & Co. The system consists of the distributing. a number of PLC inputs of a station are of course also connected with PLC outputs of neighbouring stations. the communication links between the stations are already prepared.4. If other MPS® Standard stations are integrated into a system.

4. Main control functions of CIROS® Advanced Mechatronics Distributing station Testing station Sorting station Optical IP_FI IP_N_FO IP_FI IP_N_FO sensors       Control  I4 Q6   I4 Q6    I4 Q6  console  I5 Q7   I5 Q7   I5 Q7   Q4 I6    Q4 I6    Q4 I6   Q5 I7    Q5 I7    Q5 I7  Additional COMM_I0 COMM_Q4  COMM_I0 COMM_Q4  COMM_I0 COMM_Q4 PLC inputs/ COMM_I1 COMM_Q5  COMM_I1 COMM_Q5  COMM_I1 COMM_Q5 outputs for COMM_I2 COMM_Q6  COMM_I2 COMM_Q6  COMM_I2 COMM_Q6 com. KG „ 572761 95 . © Festo Didactic GmbH & Co. Input I5 is coupled to an EMERGENCY-STOP and indicates whether or not EMERGENCY-STOP is available. PLC inputs/outputs COMM_I0 to COMM_I7 and COMM_Q0 to COMM_Q7 are only available in the case of the virtual MPS® stations for communication. Real MPS® stations do not have these inputs/outputs for communication as standard. COMM_I3 COMM_Q7  COMM_I3 COMM_Q7  COMM_I3 COMM_Q7 munication COMM_Q0 COMM_I4  COMM_Q0 COMM_I4  COMM_Q0 COMM_I4 COMM_Q1 COMM_I5  COMM_Q1 COMM_I5  COMM_Q1 COMM_I5 COMM_Q2 COMM_I6  COMM_Q2 COMM_I6  COMM_Q2 COMM_I6 COMM_Q3 COMM_I7  COMM_Q3 COMM_I7  COMM_Q3 COMM_I7 The prepared default communication links for an MPS® Standard system Note PLC input I5 must be used for communication transfer. The tables below list the allocation of the symbolic PLC addresses used for communication to the absolute PLC addresses.

6 Q7 Q1.6 Q6 Q1.6 I6 I1.7 IP_FI I0.2 COMM_I2 I2.7 I7 I1.5 I5 I1.0 COMM_I0 I2.1 COMM_I1 I2.2 COMM_I2 I2.4 I4 I1.7 I4 I1.7 IP_N_FO Q0.4 Q4 Q1.7 Q4 Q1. Main control functions of CIROS® Advanced Mechatronics Distributing station Testing station Sorting station Symbolic Absolute Symbolic Absolute Symbolic Absolute address address address address address address IP_FI I0.7 IP_N_FO Q0.7 Q7 Q1.4 I5 I1.5 Q5 Q1.4 Q5 Q1.5 Q5 Q1.1 COMM_I2 I2.7 I7 I1.7 COMM_I0 I2.0 COMM_I0 I2.4 I4 I1.0 COMM_I1 I2.4 Q4 Q1.6 I7 I1.4.7 Q7 Q1.6 I6 I1.1 COMM_I1 I2.5 I5 I1.6 Q6 Q1.5 Q6 Q1.5 I6 I1.2 96 © Festo Didactic GmbH & Co. KG „ 572761 .

2 COMM_Q3 Q2.3 COMM_Q3 Q2.4 COMM_Q4 Q2.7 COMM_Q7 Q2.4.4 COMM_Q4 Q2. However. the optical StationLink sensors are used for the transmission of communication information.7 COMM_Q7 Q2. Multi-bit communication is essentially realised via I/O connection.1 COMM_Q1 Q2.0 COMM_Q0 Q2.6 COMM_I7 I2.5 COMM_I5 I2.3 COMM_I3 I2. in addition to the coupling of PLC inputs and outputs.5 COMM_Q5 Q2. As soon as the stations of a system are correctly positioned and connected by means of the coupling points.7 COMM_Q0 Q2.4 COMM_I5 I2.5 COMM_Q5 Q2.7 COMM_I7 I2.2 COMM_Q2 Q2. KG „ 572761 97 .6 COMM_Q7 Q2.1 COMM_Q2 Q2. Main control functions of CIROS® Advanced Mechatronics Distributing station Testing station Sorting station Symbolic Absolute Symbolic Absolute Symbolic Absolute address address address address address address COMM_I3 I2.2 COMM_Q2 Q2. the prepared default I/O communications links are also automatically established.4 COMM_Q5 Q2. © Festo Didactic GmbH & Co.0 COMM_Q1 Q2.5 COMM_I5 I2.3 COMM_I3 I2.6 COMM_I6 I2.5 COMM_Q6 Q2.6 COMM_I6 I2.3 COMM_Q4 Q2.1 COMM_Q1 Q2.6 COMM_Q6 Q2.7 COMM_I7 I2.4 COMM_I4 I2.7 Allocation of symbolic PLC addresses to the absolute PLC addresses for a number of MPS® Standard stations MPS® 500-FMS systems In MPS® 500-FMS systems.3 COMM_Q3 Q2. multi-bit communication is available as standard.0 COMM_Q0 Q2.4 COMM_I4 I2.6 COMM_Q6 Q2.3 COMM_I4 I2.5 COMM_I6 I2.

They are automatically established during modelling or via the press of a button (Modeling/I/O Configuration/Create Communication Links).4. To enable you to work promptly with a networked system. The communication interfaces between all stations are described in CIROS® Advanced Mechatronics Assistant. whereby specific PLC inputs and outputs of a station are connected to the PLC inputs and outputs of neighbouring stations. 98 © Festo Didactic GmbH & Co. KG „ 572761 . activate the Examples and Models of CIROS® Advanced Mechatronics command in the Help menu. Different PLC inputs and outputs are available for the transmission of communication information. the communication links between the stations are prepared. To open CIROS® Advanced Mechatronics Assistant. All I/O communication links established for an MPS® system can be identified in the Manual Operation window. The sample PLC programs provided use a part of these communication links. The prepared communication links are shown as examples for an MPS® 500-FMS system. The station consists of the transport system station and the distributing and testing stations in the form of product input. Main control functions of CIROS® Advanced Mechatronics The information exchange between the system stations during simulation can take place. Technical documentation and information regarding the sample PLC program of a station can be found in CIROS® Advanced Mechatronics Assistant. Both the absolute and symbolic addresses of the PLC inputs/outputs of a station used for communication can be found in the allocation list of the sample PLC program.

© Festo Didactic GmbH & Co. PLC input I5 of the individual stations must not be used for communication transfer. COMM_I3 COMM_Q7  COMM_I3 COMM_Q7  ST1_COMM_I3 cation COMM_Q0 COMM_I4  COMM_Q0 COMM_I4  ST1_COMM_Q0 COMM_Q1 COMM_I5  COMM_Q1 COMM_I5  ST1_COMM_Q1 COMM_Q2 COMM_I6  COMM_Q2 COMM_I6  ST1_COMM_Q2 COMM_Q3 COMM_I7  COMM_Q3 COMM_I7  ST1_COMM_Q3 The prepared default communication links for a small MPS® 500-FMS system. only working position 1 of the transport system is allocated Note The transport system station has the communication interface shown for each working position. Input I5 is coupled to the EMERGENCY- STOP and indicates whether or not EMERGENCY-STOP is available>. KG „ 572761 99 . Main control functions of CIROS® Advanced Mechatronics Distributing station Testing station Transport system station Optical IP_FI IP_N_FO IP_FI sensors     Control  I4 Q6   I4 ST1_OUT0 console  I5 Q7   I5 ST1_OUT1 I6  ST1_OUT2 I7   ST1_OUT3  Q4 I6   Q4 ST1_IN0  Q5 I7   Q5 ST1_IN1 Q6  ST1_IN2 Q7   ST1_IN3 Additional COMM_I0 COMM_Q4  COMM_I0 COMM_Q4  ST1_COMM_I0 PLC inputs/ COMM_I1 COMM_Q5  COMM_I1 COMM_Q5  ST1_COMM_I1 outputs for COMM_I2 COMM_Q6  COMM_I2 COMM_Q6  ST1_COMM_I2 communi. A 1-signal is applied at input 15 if EMERGENCY-STOP is not actuated.4. The working position is identical to the stopper position.

7 I7 I1. Real MPS® stations do not have these input/outputs as standard for communication.6 Q6 Q1.1 I6 I1.0 Q5 Q1.2 I7 I1. The tables show the allocation of the symbolic PLC addresses used for communication to the absolute PLC addresses.7 IP_FI I0. ST1_COMM_Q0 to ST1_COMM_Q3 are only available for communication for the virtual MPS® stations.6 ST1_OUT 2 Q2.7 Q7 Q1. COMM_Q0 to COMM_Q7.5 Q5 Q1.0 I5 I1. A description of the communication interfaces between all the stations of an MPS® 500-FMS system and therefore also of the prepared default communication links can be found in CIROS® Advanced Mechatronics Assistant.7 I4 I1.6 ST1_IN2 I2.6 I6 I1. ST1_COMM_I0 to ST1_COMM_I3.1 Q6 Q1.4 I4 I1. Distributing station Testing station Transport system station Symbolic Absolute Symbolic Absolute Symbolic Absolute address address addresse address address address IP_FI I0.7 IP_N_FO Q0.4 Q4 Q1. Main control functions of CIROS® Advanced Mechatronics PLC inputs/outputs COMM_I0 to COMM_I7.7 ST1_IN3 I2. KG „ 572761 .5 ST1_IN1 I2.3 100 © Festo Didactic GmbH & Co.3 Q4 Q1.5 ST1_OUT 1 Q2.2 Q7 Q1.4 ST1_OUT0 Q2.5 I5 I1.7 ST1_OUT 3 Q2.4.4 ST1_IN0 I2.

5 COMM_Q6 Q2.0 ST1_COMM_I0 I2.7 COMM_I4 I2.7 COMM_Q7 Q2.2 COMM_I2 I2.7 COMM_I7 I2.5 COMM_I6 I2.6 ST1_COMM_Q2 Q2.7 Allocation of symbolic PLC addresses to the absolute PLC addresses for a number of MPS® 500-FMS stations © Festo Didactic GmbH & Co.6 COMM_I6 I2.5 ST1_COMM_Q1 Q2.6 COMM_Q7 Q2.6 COMM_Q6 Q2.6 COMM_I7 I2.0 COMM_I0 I2.2 ST1_COMM_I2 I2.5 COMM_I5 I2.3 ST1_COMM_I3 I2.4 COMM_Q5 Q2.7 COMM_Q0 Q2.4 COMM_Q4 Q2.1 COMM_Q1 Q2.3 COMM_Q4 Q2.4 ST1_COMM_Q0 Q2.2 COMM_Q3 Q2. KG „ 572761 101 .4.5 COMM_Q5 Q2.7 ST1_COMM_Q3 Q2.0 COMM_Q1 Q2.4 COMM_I1 I2.1 COMM_Q2 Q2.3 COMM_I3 I2.1 COMM_I1 I2.5 COMM_I2 I2.3 COMM_Q3 Q2. Main control functions of CIROS® Advanced Mechatronics Distributing station Testing station Transport system station Symbolic Absolute Symbolic Absolute Symbolic Absolute address address address address address address COMM_I0 I2.4 COMM_I5 I2.0 COMM_Q0 Q2.1 ST1_COMM_I1 I2.2 COMM_Q2 Q2.4 COMM_I4 I2.6 COMM_I3 I2.

102 © Festo Didactic GmbH & Co. The communication variable for working position 2. Process Activities are displayed in the lefthand part of the window. You can change the value of these variables in that you can for example apply 1-signal at a communication input or a valve coil. The name of the communication variable includes a reference to the working position for the purpose of differentiation. KG „ 572761 . the processing working position. Main control functions of CIROS® Advanced Mechatronics Note The transport system station has the communication interface shown for each of the six working positions. Examples of process activities are sensor signals or also the values of communication outputs.e. These are the variables to which the process model simulation reacts. The user cannot change the value of these variables. starts with ST2_. These variables do of course have a different absolute address than the variable starting with ST1_. i. Display of communication Communication links are created and displayed in the Manual links Operation window. You will find the complete list of the communication variables of the transport system station in CIROS® Advanced Mechatronics Assistant. The righthand part of the window shows the process activities. The working position is identical to the stopper position. These are the variables which adjust the simulation of the process model. The status of a communication link is identified by the graphic representation of the connection.4.

KG „ 572761 103 . The signal flow of a communication links runs from right to left. Green: Link has the value 1. Red: Link has the value 0. The status of a communication link can be identified by the colour of the links: Blue: Link is selected. Communication links form part of the I/O connections. Main control functions of CIROS® Advanced Mechatronics Communication links are shown in the middle section. You can see this by the orientation of the arrow at the end of the links. © Festo Didactic GmbH & Co.4.

the distributing and testing stations in the form of product input and the handling and sorting stations in the form of product output. Make sure that the desired MPS® is loaded. The example selected shows an MPS® 500-FMS system. 104 © Festo Didactic GmbH & Co. KG „ 572761 . This system consists of a transport system. Main control functions of CIROS® Advanced Mechatronics This is how you establish the prepared default communication links 1.4.

open the Manual Operation window by activating the Manual Operation command in the Modeling window. If the middle section of the window with the heading I/O Connections is not displayed. 3. KG „ 572761 105 . © Festo Didactic GmbH & Co. Check whether the communication links have already been established via the coupling of PLC inputs and outputs. You open the context-sensitive menu by moving the mouse pointer into the Manual Operation window and then pressing the right mouse button. Select the command Show I/O connections.4. Main control functions of CIROS® Advanced Mechatronics 2. then open the context-sensitive menu via the right mouse button. To do so.

also the communication links. 5. Double click the + symbol in front of the individual stations in the Manual Operation window to display the entries regarding all the stations and. insofar as available. No communication links are displayed in the I/O Connections window. no communication links are established. Therefore. 106 © Festo Didactic GmbH & Co. They have been deleted by the user at an earlier stage. To create the prepared default communication links activate the Create Communication Links command in the Modeling menu under I/O Confiuration. Main control functions of CIROS® Advanced Mechatronics 4.4. KG „ 572761 .

Main control functions of CIROS® Advanced Mechatronics 6. You can now simulate the running of the prepared PLC programs. 7. you need to create the communication links using the described menu commands. Provided that you do not make any changes to the PLC programs and the communication interfaces. © Festo Didactic GmbH & Co. With MPS® Standard systems the prepared communication links are not automatically created via I/O connection. KG „ 572761 107 . If you want to realise multi-bit communication for MPS® Standard systems via I/O connection and use the prepared communication links for this. The communication links are set up and shown in the Manual Operation window under I/O Connections in the form of graphic connections between the respective communication input/outputs. Note In the case of MPS® 500-FMS systems the default communication links used are already created automatically via I/O connection during the modelling.4. you do not need to create the communication links.

The selected example shows an MPS® 500-FMS system. Main control functions of CIROS® Advanced Mechatronics This is how you delete the default communication links 1. KG „ 572761 . the distributing and testing stations in the form of product input and the handling and sorting stations as product output.4. Make sure that the desired MPS® system is loaded. The system consist of a transport system. 108 © Festo Didactic GmbH & Co.

You can establish this in the Manual Operation window in the I/O Connections section. The same applies for the product output and transport system stations. Delete individual communication connections with the command Remove I/O Connection in the context sensitive menu for the manual operation window. © Festo Didactic GmbH & Co. All default communication links are now deleted. Main control functions of CIROS® Advanced Mechatronics 2. KG „ 572761 109 .4. 3. This command does not delete user-defined communication links. Activate the Delete Communication Links command under I/O Configuration in the Modeling menu. Connections are displayed neither between the communication inputs/outputs of the distributing and testing stations nor between the communication input/outputs of the testing and transport system stations. Note The Delete Communication links command deletes all default communication links.

1. Main control functions of CIROS® Advanced Mechatronics This is how you create user-defined communication links You can create or delete individual communication links yourself at any time. It is however important that you use communication interfaces other than the prepared default interfaces in the PLC programs for the stations of your system or. The selected example displays an MPS® Standard system. Load the desired MPS® system. KG „ 572761 . if you only want to create exactly those connections which are evaluated by the PLC programs. for example.4. which consists of the distributing. 110 © Festo Didactic GmbH & Co. testing and sorting stations.

No connections are shown between the communication inputs and outputs of the stations. none of the communication links for the system have been created as yet. Open the context-sensitive menu by moving the mouse pointer into the Manual Operation window and then pressing the right mouse button. Double click the + Symbol in front of the stations to display all entries regarding the stations. then open the context-sensitive menu via the right mouse button. 3. KG „ 572761 111 . This window is divided into three parts. Consequently. Select the Show I/O Connections command.4. Open the Manual Operation window by clicking onto the Manual Operation command in the Modeling menu. © Festo Didactic GmbH & Co. Main control functions of CIROS® Advanced Mechatronics 2. If the middle part of the window with the heading I/O Connections is not shown.

4. On the lefthand side of the window scroll down the items of the distributing station into the viewable section. Main control functions of CIROS® Advanced Mechatronics 4. 5. 112 © Festo Didactic GmbH & Co. You require a connection between the PLC output Q4 Communication of the testing station and the PLC input I6 Communication of the distributing station. KG „ 572761 . In the righthand section of the window scroll down the items of the testing station into the viewable area of the window.

click onto the Q4 Communication line of the testing station. KG „ 572761 113 . © Festo Didactic GmbH & Co. You can now establish the connections. Then release the mouse button again. The communication link has now been created. move the mouse pointer to the arrow next to the entry I6 Communication of the distributing station. Press the left mouse button and whilst holding down the left mouse button. 7.4. Move the mouse pointer onto the blue double arrow next to the highlighted entry. The line is now highlighted. the entry 16 Communication of the distributing station connected to this output is automatically highlighted. To establish the desired connection. The mouse pointer now changes into a rectangle with connection lines. Main control functions of CIROS® Advanced Mechatronics 6. If you now click onto Q4 Communication of the testing station.

You now need to select the desired output Q6 Communication of the distributing station in the righthand window under Process Status. 114 © Festo Didactic GmbH & Co. 9.4. Next. Main control functions of CIROS® Advanced Mechatronics 8. KG „ 572761 . On the lefthand side of the window then scroll the 14 Communication entry of the testing station into the viewable section of the window. you want to establish a connection between the PLC input I4 Communication of the testing station and the PLC output Q6 Communication of the distributing station.

The entry is now highlighted. To establish the desired connection. Press the left mouse button and. Proceed in the same way if you require further communication links between the stations of your system. You can now establish the connection. The mouse pointer now changes into a rectangle with connecting lines. © Festo Didactic GmbH & Co.4. Main control functions of CIROS® Advanced Mechatronics 10. 11. The communication link is now set up. then release the mouse button again. Then move the mouse pointer onto the blue double arrow next to the highlighted entry. whilst holding down the mouse button. click onto the entry Q6 Communication of the distributing station. KG „ 572761 115 . move the mouse pointer up to the arrow next to the 14 Communication entry of the testing station.

116 © Festo Didactic GmbH & Co. testing and sorting stations. which consists of the distributing. The example selected displays an MPS® Standard system. KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics This is how you delete user-defined communication links 1. Load the desired MPS® system.4.

4. 3. Main control functions of CIROS® Advanced Mechatronics 2. Open the Manual Operation window by clicking onto the Manual Operation command in the Modeling menu. Double click the + symbol of the individual stations to display the entries for the stations. To do so. move the mouse pointer into the Manual Operation window and then press the right mouse button. If the middle section of the window with the heading I/O Connections is not displayed. Now select the Show I/O Connections command. KG „ 572761 117 . then open the context-sensitive menu via the right mouse button. © Festo Didactic GmbH & Co.

118 © Festo Didactic GmbH & Co. whose connection you want to delete. KG „ 572761 . this is the I4 Communication entry of the testing station. Main control functions of CIROS® Advanced Mechatronics 4. Click onto the entry. If you want to see the communication output with which 14 Communication is connected. then scroll down in the righthand section of the window until the connection is fully displayed.4. In this exampIe.

Click onto the I4 Communication entry of the testing station again or onto the associated entry Q6 Communication of the distributing station. KG „ 572761 119 . The communication link has been deleted. © Festo Didactic GmbH & Co. 6. Open the context-sensitive menu via the right mouse button and select the Remove IO Connection command.4. Main control functions of CIROS® Advanced Mechatronics 5.

The communication links are thus correctly established. Main control functions of CIROS® Advanced Mechatronics 4.5 The production run of the system can be simulated as soon as a system Simulating a system is modelled and the necessary communication links are set up. 120 © Festo Didactic GmbH & Co. If the stations are correctly positioned.4. The following preconditions must be fulfilled for MPS® Standard systems: The stations must be correctly positioned next to each other and connected. KG „ 572761 . then the position and alignment of the StationLink sensor which transmit the communication signal are also correct.

The PLC program can be executed either via the internal S7 PLC or an external controller. The communication links between the PLC inputs and outputs of the stations must be established. the individual process components will behave differently during simulation than expected. If you are using the default settings of the software. then the user can systematically control individual process components of the system by using the manual operation window functions. KG „ 572761 121 . The PLC program can be executed either via the internal S7 PLC or an external controller. then the sample PLC program of the station is automatically loaded to the internal S7 PLC and executed. This is effected automatically for the prepared communication links as a result of the correct positioning and alignment of the stations on the transport system. If you are using the default settings of the software. © Festo Didactic GmbH & Co. If no PLC program is active. Note The user can disconnect the connection between station models and PLC selectively in order to manually control individual process components. The prerequisites for MPS® 500-FMS systems are as follows: The stations must be correctly positioned and aligned with the transport system. Main control functions of CIROS® Advanced Mechatronics A PLC program which controls the operation of the station must be available for each station. A PLC program must be available for each station. If you simulate a system that is incorrectly configured. then the sample PLC program of the station is automatically loaded to the internal S7 PLC and executed when simulation is started. then the user can selectively control individual process components of the system using the manual operation window functions. If no PLC program is active. which controls the operation of the station.4.

Note In CIROS® Advanced Mechatronics the two simulation modes Cycle and Running are identical. Stopped: The simulation mode is not active. The file name and path data of the loaded system are shown in the header line.4. 122 © Festo Didactic GmbH & Co. you can monitor the visual simulation and therefore the production sequence of the system in the activity window. Cycle: The system is being simulated. The field on the left indicates the simulation time. Certain information is always available to you. Running: The system is being simulated. KG „ 572761 . The system is not being simulated Not simulated. The status bar informs you regarding the operating status of the system: A field to the right displays whether simulation is active or stopped. Main control functions of CIROS® Advanced Mechatronics As soon as system simulation is active.

Alternatively you can also activate simulation via the Start Cycle menu entry or via the Stopped button in the status bar. The simulation is active. Activate the Start command in the Simulation menu. You can identify the simulation mode in the status line via the Running entry. KG „ 572761 123 . © Festo Didactic GmbH & Co. 2. Make sure that the system is in the initial position by executing the Reset Workcell command in the Simulation menu. click Stop in the Simulation menu. 3. Alternatively you also click onto the Running field in the status bar. To stop simulation. Main control functions of CIROS® Advanced Mechatronics This is how simulation is switched on and off again 1.4.

4. Main control functions of CIROS® Advanced Mechatronics

As soon as simulation is active, you can operate and monitor the
system.

Note Proceed as follows if you want to save a modelled system after
simulation is executed: First activate the command Reset Workcell in
the Simulation menu. The system moves into the initial position. All
workpieces are removed. Then activate the required command to save
the system.

4.6 If system simulation is active, you can operate each station controlled
Operating and monitoring via the sample PLC program using the pushbuttons and switches of the
a system corresponding control console. You can identify the status of simulation
on the status bar.

Process module

Control console of MPS Standard station Control console of transport system station

I4

I5
Start Stop

Q4

Reset Auto/Man
Q5

GND
Q1 Q2

I/O

124 © Festo Didactic GmbH & Co. KG „ 572761

4. Main control functions of CIROS® Advanced Mechatronics

Depending on the system combination, different production processes
are executed. Pneumatic cylinders or measuring instruments can be
produced. The individual production processes require different
workpieces. Missing parts are designated for individual stations.

Workpieces Suitable for systems with

Correct workpieces: Basic Processing station
cylinder body of different types Storage station
Buffer station
Testing station
Black
Robot station
Robot assembly station
Red Sorting station
Separating station
Metal Distributing station

Workpiece of incorrect height Processing station
and incorrectly drilled hole: Testing station
Basic cylinder body

Blue

Correct workpieces: Processing station
Housings for measuring Fluidic Muscle Press station
instruments in different designs Storage station
Pick & Place station
Buffer station
Black
Testing station
Sorting station
Red Separating station
Distributing station
Metal

© Festo Didactic GmbH & Co. KG „ 572761 125

4. Main control functions of CIROS® Advanced Mechatronics

Workpieces Suitable for systems with

Correct intermediate product: Fluidic Muscle Press
Housing for measuring Storage station
instrument with applied Buffer station
measuring insert in different
designs

Black

Red

Metal

Workpiece for MPS® Standard systems

126 © Festo Didactic GmbH & Co. KG „ 572761

4. Main control functions of CIROS® Advanced Mechatronics

Workpieces Suitable for systems with

Correct workpieces: Basic Distributing station
cylinder body of different types Testing station
Processing station
Handling station
Black
Quality assurance station
Sorting station
Red Robot assembly station
Storage station
Metal

Workpiece of incorrect height Testing station
and incorrectly drilled hole

Blue

Working with incorrectly drilled Processing station·
hole: Quality assurance station
Housing for measuring Robot assembly station
instrument in different designs

Black

Red

Metal

Workpieces for MPS® 500-FMS systems

© Festo Didactic GmbH & Co. KG „ 572761 127

4. Main control functions of CIROS® Advanced Mechatronics

As soon as you create a new system, a table with the possible
workpieces is displayed as standard. If simulation is active, then select
the workpiece from this table which you want to use for the production
process of the system.

128 © Festo Didactic GmbH & Co. KG „ 572761

4. Main control functions of CIROS® Advanced Mechatronics

This is how you operate an MPS® Standard system where the
individual stations are controlled via the sample PLC programs

1. Make sure that the system is in the initial position and that there are
no workpiece on the stations. You realise this by activating the
Reset Workcell command in the Simulation menu.

2. Start simulation by clicking the Start command in the Simulation
menu.
3. The illuminated Reset button now prompts the reset function on all
stations.

© Festo Didactic GmbH & Co. KG „ 572761 129

6. Carry out the reset function for each station by clicking onto the Reset button. Main control functions of CIROS® Advanced Mechatronics 4. We recommend that you carry out the resetting of the individual stations against the material flow. KG „ 572761 . In the case of the system shown this means that the magazine of the distributing station must be filled with workpieces.4. Make sure that workpieces are available for the production process of the system. 130 © Festo Didactic GmbH & Co. The illuminated Start button of a station indicates that the corresponding station is now in the initial position and the start precondition is fulfilled. 5.

Then click onto the symbolic workpiece on the distributing station. this workpiece cannot not be generated for the station. All workpieces are realised in the form of buttons. KG „ 572761 131 . a red basic cylinder body. The selected workpiece. © Festo Didactic GmbH & Co. Main control functions of CIROS® Advanced Mechatronics 7. is shown as „pressed“.4. If you have selected a workpiece which cannot be processed by a station. Note Not every workpiece is suitable for every station. Click onto the desired workpiece on the table of workpieces. With each mouse click the magazine is filled with the workpiece selected.

You can interrupt the sequence of a station at any time by pressing the STOP button. KG „ 572761 . 132 © Festo Didactic GmbH & Co. Start the sequence of each station by clicking onto the Start button. 10. We recommend that you start the stations in the sequence in which they are arranged in the material flow. With the key actuator you can choose between continuous cycle (switch position vertical) and individual cycle (switch position horizontal) for the sequence of a station. you need to carry out the Reset function beforehand.4. If you want to restart the station. This starts the automatic mode of the station. Main control functions of CIROS® Advanced Mechatronics 8. 9.

Note Slides filled with workpieces. KG „ 572761 133 . can be emptied via appropriate commands in the manual operation window. you can selectively trigger the process actuators manually. © Festo Didactic GmbH & Co. You will need the manual operation window functions for this. Main control functions of CIROS® Advanced Mechatronics If a station is controlled via a PLC program you have created. If a station is not controlled via a PLC program. which result in the production process stopping. then you will know how the running and operation of the station are defined.4.

4. KG „ 572761 . This applies in particular to the pallets of the transport system station. the storage slots of the automated warehouse station and the slides of the sorting station. Remove all workpieces by activating the Reset Workcell command in the Simulation menu. Make sure that the system is in the initial position and that there are no workpieces on the stations. Main control functions of CIROS® Advanced Mechatronics This is how you operate an MPS® 500-FMS system where the individual stations are controlled via the sample PLC programs The operation of an MPS® 500-FMS system is described using the example of a fully expanded MPS® 500-FMS system. 134 © Festo Didactic GmbH & Co. 1.

Main control functions of CIROS® Advanced Mechatronics 2. 3. The master switch is located on the side of the control cabinet of the transport system station. The starting of simulation causes the master switch on the system to be switched on. Click onto the Automatic On button. The master switch supplies the whole system with power. Start the simulation by clicking the Start command in the Execute menu.4. KG „ 572761 135 . you start the transport system station. 4. The transport system is running and the Automatic Off button is illuminated. The flashing Automatic On button prompts the start function. First. © Festo Didactic GmbH & Co.

the illuminated Reset button prompts the reset function. 136 © Festo Didactic GmbH & Co. KG „ 572761 . Processing.4. Main control functions of CIROS® Advanced Mechatronics 5. Carry out the reset function for the stations mentioned by clicking onto the Reset button. In the case of the stations at the operating positions Product Input. 6. Assembly and Product Output.

The axis carries out reference travel and the Start button flashes when the initial position is reached. 8. for reasons specific to this station. switch the AUTO/MAN key actuator into the MAN position (switch position horizontal) by clicking onto the AUTO/MAN key actuator. © Festo Didactic GmbH & Co. To reset the station. However. In the case of the automated warehouse station it is equally mandatory to carry out the reset function. Main control functions of CIROS® Advanced Mechatronics 7. KG „ 572761 137 .4. The flashing Reset button indicates that the station can now be reset. Click onto the Reset button. the reset sequence of the automated warehouse station is different to that of the MPS®s stations. The automated storage station moves into the initial position.

e. Automatic operation of the station can only be started in this switching position. KG „ 572761 . Now switch the AUTO/MAN key actuator to the AUTO switching position (switch position vertical). 11. 138 © Festo Didactic GmbH & Co. The illuminated Start button on the MPS® stations indicates that the corresponding stations are in the initial position and that the start precondition is fulfilled. the start precondition for this station is also fulfilled. with basic cylinder bodies. i. Start the sequence of the station by clicking the Start button.4. The Start button is illuminated. 10. Main control functions of CIROS® Advanced Mechatronics 9. As soon as you have filled the magazine of the distributing station with workpieces.

With each mouse click the magazine is filled with the workpiece selected. The selected workpiece. Start the sequence of each station by clicking onto the Start button. 13. is shown depressed. © Festo Didactic GmbH & Co. Main control functions of CIROS® Advanced Mechatronics 12. 14.4. With the AUTO/MAN key actuator you can choose between continuous cycle (switching position vertical) and individual cycle (switching position horizontal) for the sequence of a station. Fill the magazine by clicking onto the desired workpiece on the workpiece table. a red basic cylinder body. KG „ 572761 139 . Then click onto the symbolic workpiece on the distributing station.

KG „ 572761 . Note regarding the The automated warehouse station only participates actively in the automated warehouse production process if product output for the process is not or is no station longer available for the process. you will know how the running and operation of the station is defined. You will need the functions of the Manual Operation window for this. If the station is not controlled via a PLC. The automated warehouse takes out workpieces if ‟ an empty pallet passes. you need to carry out the Reset function beforehand. can be emptied using appropriate commands in the Manual Operation window. Note regarding the quality The quality assurance station identifies the housing for a measuring assurance station instrument as a reject part. The robot then rejects the transferred reject part. The station passes on this information to the transport system station and the transport system station passes on the information to the robot assembly station. You can interrupt the sequence of a station at any time by pressing the STOP button. Note If a station is controlled via a PLC program you have created.4. 140 © Festo Didactic GmbH & Co. Slides filled with workpieces and which result in the production process stopping. In concrete terms this means: The automated warehouse stocks up if ‟ one or both stations of product output are not started or ‟ the slides at product output are full. you selectively trigger the process actuators manually. Main control functions of CIROS® Advanced Mechatronics 15. If you want to restart the station.

© Festo Didactic GmbH & Co. The LEDs on the inputs/outputs on the control console. the connection is highlighted in blue. provided for the I/O connection. In the windows Inputs and Outputs you can identify the status of the PLC signals for the station selected. The designation of a component is shown by clicking onto the connection or the LED of a process component. If air is applied at a cylinder connection. The pneumatic tubing itself is not shown. indicate the status of the communication signals. These form part of the valves which supply the supply port with air.4. One exception is the designations of the supply ports. This designation is identical to the designation in the circuit diagram. Main control functions of CIROS® Advanced Mechatronics This is how the status of an MPS® system is indicated LEDs on the sensors and valves indicate the electrical status of the process components. The Manual Operation window provides you with an overview of all process statuses and process activities of the system and also displays all the communication links. KG „ 572761 141 .

Main control functions of CIROS® Advanced Mechatronics 142 © Festo Didactic GmbH & Co. KG „ 572761 .4.

Click onto the top entry. The settings for this are effected in model explorer. In the Visualisation section click onto the two check boxes for the entries Show Measuring Range and Show Measured Value(s). Now activate the context-sensitive menu via the right mouse button and select the Properties command.4. The window Properties for workcell is displayed. Activate the Sensor Simulation register. A tree structure is displayed. the entry is MPS® 500. In the case of an MPS® 500-FMS system. Main control functions of CIROS® Advanced Mechatronics Note You can also display additional information regarding the sensors. KG „ 572761 143 . Both boxes are now shown with a tick. © Festo Didactic GmbH & Co. Activate the command Model Explorer in the Modeling menu.

The respective sensor lines are now shown in the system. 144 © Festo Didactic GmbH & Co. KG „ 572761 .4. Main control functions of CIROS® Advanced Mechatronics Close the Properties for workcell window. Close the Model Explorer window.

KG „ 572761 145 .4. move.7 You can freely adjust the perspective view of a modeled system. With a Changing the view of a few central commands you can rotate. enlarge or minimize the system representation of the process model. Main control functions of CIROS® Advanced Mechatronics 4. © Festo Didactic GmbH & Co.

Main control functions of CIROS® Advanced Mechatronics The perspective view is defined by the coordinates of the viewer (= standpoint) and a reference point of the process model (= mid point). Reference point Turn Angle Z Y X Definition of perspective view 146 © Festo Didactic GmbH & Co.4. KG „ 572761 .

The view then changes accordingly. Move the mouse pointer in the Z or X direction. 2. 4. 3. © Festo Didactic GmbH & Co. Release the mouse pointer again. The mouse pointer now changes into a small coordinate system. hold down the Alt key and left mouse button and move the mouse. which indicates the direction in which the standpoint and reference point can be moved. Hold down the left mouse button. Activate the Rotate command in the View menu. KG „ 572761 147 . You can also activate the Move command by holding down the Shift key and then pressing the left mouse button. which indicates the direction in which the standpoint and reference point can be moved. Move the mouse pointer in the Z or X direction.4. 2. You can also activate the Rotate command by holding down the Ctrl key and then pressing the left mouse button. 4. Hold down the left mouse button. Activate the Move command in the View menu. Release the mouse pointer again. To tilt the system in any direction. Main control functions of CIROS® Advanced Mechatronics This is how you move the modeled system 1. This is how you rotate the modeled system 1. A dashed arrow means that it is not possible to move into the corresponding direction. The view then changes accordingly. A dashed arrow means that it is not possible to move in the corresponding direction. 3. The mouse pointer changes into a small coordinate system.

Release the right mouse button and the section is now enlarged. 3. you can easily enlarge or minimise the system view by using the scroll wheel. Activate the Zoom command in the View menu. 148 © Festo Didactic GmbH & Co. This is how you enlarge the view Activate the Zoom-In command in the View menu. If you want to reduce the view. The picture is enlarged to 125%. KG „ 572761 . 2. Hold down the key combination Shift+Ctrl. This is how you reduce the view Activate the Zoom-Out command in the View menu. This is how you enlarge a specific section 1. You can also activate the Zoom command by holding down the key combination Shift+Ctrl and then pressing the left mouse button. A frame is now displayed. By moving the mouse. The mouse pointer changes into two squares. 5. The picture is now reduced to 80%. 2. then hold down the left mouse button and move the mouse pointer in the direction of the arrow. then hold down the left mouse button and move the mouse pointer against the direction of the arrow. Main control functions of CIROS® Advanced Mechatronics This is how you enlarge or reduce the view 1. 3. If you have a mouse with a scroll wheel. Position the mouse pointer on a corner of the section. If you want to enlarge the view. place the frame around the section you want to enlarge.4. Press the right mouse button and move the mouse. 4.

g. Panel_I6. Panel_Q6. e. Main control functions of CIROS® Advanced Mechatronics 4. If the input or output signal is forced. the value is shown in angle brackets. Panel_I7. <1>. Panel_Q4.4.8 The Inputs and Outputs windows show which signals are applied at the The Inputs and Outputs inputs and outputs of the PLC for the selected station. Panel_Q5. KG „ 572761 149 . Panel_Q7 for the PLC inputs/outputs available on the control console for I/O connection. In MPS® Standard systems you will find Panel_I4. The PLC inputs/outputs available for communication are designated differently in MPS® Standard systems and MPS® 500-FMS systems. COMM_Q0 … COMM_Q7 as additional inputs/outputs for I/O connection. © Festo Didactic GmbH & Co. 0 signals are windows shown in red and 1 signals in green. COMM_I0 … COMM_I7.

whereby PLC inputs/outputs can be allocated to the individual stopper positions. PLC inputs/outputs of the transport system station have an identifier. Main control functions of CIROS® Advanced Mechatronics In MPS® 500-FMS systems for example. 150 © Festo Didactic GmbH & Co.4. KG „ 572761 .

© Festo Didactic GmbH & Co. Make sure that the desired system is loaded and simulation is active. Main control functions of CIROS® Advanced Mechatronics This is how you open the Inputs window 1. KG „ 572761 151 .4.

Select the station whose PLC inputs you wish to observe. KG „ 572761 . for example via the Start command in the Simulation menu. Select the desired PLC in the Current column via a mouse click. 152 © Festo Didactic GmbH & Co. the execution of the PLC programs in the active controllers is also stopped. Main control functions of CIROS® Advanced Mechatronics 2. If system simulation is stopped.4. The status as to whether or not a PLC is operating is shown in the Start/Stop column. Note The Controller Selection window displays all the stations of the modelled system which have their own internal controller. To do so. then the PLC programs of the active controllers are started in sequence4. If system simulation is started. click onto the Controller Selection in the Programming menu. The controllers are switched to active by default.

use for example the Open command in the File menu. © Festo Didactic GmbH & Co. To do so. So that you know which process signal it is. the signal names include the relevant designations from the circuit diagrams. Main control functions of CIROS® Advanced Mechatronics The status of PLC inputs/outputs is displayed in the Inputs/Outputs window only for the controller selected as Current. Activate Inputs/Outputs in the View menu and select Show Inputs. KG „ 572761 153 . 3. Example: STATION_1B2: The PLC input which is connected to sensor 1B2. Also. PLC programs can be loaded to the selected internal controller.4.

4. Main control functions of CIROS® Advanced Mechatronics This is how you open the Outputs window 1. KG „ 572761 . Make sure that the desired system is loaded and simulation is active. 154 © Festo Didactic GmbH & Co.

then the execution of the PLC programs is also stopped in the active controllers. for example via the Start command in the Simulation menu. KG „ 572761 155 . the PLC programs of the active controllers are started in sequence. Select the stations whose PLC you wish to observe by clicking onto the Controller Selection command in the Programming menu. The status as to whether or not a PLC is operating is displayed in the Start/Stop column. Main control functions of CIROS® Advanced Mechatronics 2. Select the desired PLC in the Current column.4. If system simulation is stopped. Note The Controller Selection window displays all the stations of the modelled system which have their own internal controller. The controllers are switched as active by default. If simulation of the system is started. © Festo Didactic GmbH & Co.

Activate Inputs/Outputs in the View menu and select Show Outputs. Main control functions of CIROS® Advanced Mechatronics The status of PLC inputs/outputs is displayed in the Inputs/Outputs window only for the controller selected as Current. To do so. PLC programs can be loaded to the selected controller.4. Also. KG „ 572761 . 156 © Festo Didactic GmbH & Co. 3. use for example the Open command in the File menu.

9 The Manual Operation window offers various functions: The Manual Operation Display of the process statuses and process activities of a system. A double click onto the minus symbol hides the entries again. By double clicking onto the + symbol of a station. Display of communication links realised via I/O connection.4. Note It is of course possible to open the Inputs and Outputs windows at the same time. all entries are displayed regarding the respective station. KG „ 572761 157 . window Controlling of individual actuators of a system. Creating of user defined communication links via I/O connection. You can also open the Inputs and Outputs windows via Workspaces in the Windows menu. The entries for the individual stations of a system are configured in a tree structure. Setting of stops in the simulation of a system. Main control functions of CIROS® Advanced Mechatronics So that you know which process signal it is the signal names include the relevant designation from the circuit diagrams. Example: STATION_1M1: The PLC output which is connected to valve coil 1M1. where you will find the frequently required window combinations. © Festo Didactic GmbH & Co. 4.

the value is shown in angled brackets. KG „ 572761 . you can change the value of this variable. The process statuses include status of sensors. Process activities are variables to which the process model simulation reacts. 1 signals are indicated by a green illuminated LED. These include primarily the actuation of valves and the controlling of communication inputs. 158 © Festo Didactic GmbH & Co. You will find the relevant command in the context-sensitive menu via the right mouse button. You can monitor all process activities in the righthand section of the window. Main control functions of CIROS® Advanced Mechatronics The lefthand section of the window displays the process activities. 1 signals are indicated by a red illuminated LED. The status of signals is also shown in the Value column. The user cannot change the value of these variables.4. valve coils and communication outputs. You can show or hide the display of the Value column. As the user. If the signal is forced. Process statuses are variables that are set and correspondingly displayed by the process model simulation. Here.

If the Value Change is not shown in colour. Communication links are shown in the middle section of the window.4. Main control functions of CIROS® Advanced Mechatronics Additional information is also displayed: If the signal status has changed since the last simulation cycle. Communication links form part of the I/O connections. the relevant line is highlighted in colour. © Festo Didactic GmbH & Co. then activate Show Value Changes in the context-sensitive menu via the right mouse button. KG „ 572761 159 . This enables you to easily identify and follow the signals that have last changed.

4. Green: Connection has the value 1. 160 © Festo Didactic GmbH & Co. You can see this by the orientation of the arrows at the connection ends. Main control functions of CIROS® Advanced Mechatronics The signal flow of a communication link runs from right to left. the respective communication user is also shown highlighted. Red: Connection has the value 0. If the middle section of the window headed I/O Connections is not displayed. You can identify the status of a communication link by the colour marking of the connection: Blue: Connection is selected. KG „ 572761 . then activate Show I/O Connections in the context-sensitive menu via the right mouse button. By clicking onto an entry for which a communication link exists.

They are taken into account in the Manual Operation window. Conversely the process generates output signals. KG „ 572761 161 .4. are input signals for the process. The Manual Operation window is used solely to manage the communication links realised via I/O connection. Process inputs and outputs on the process side. for example sensor signals. which are then connected to a PLC input. These connections between PLC inputs/outputs and process inputs/outputs also form part of the I/O connections and are required internally by CIROS® Advanced Mechatronics. The table below provides an overview of the meaning of the symbols by the entries in the window section I/O Connections. © Festo Didactic GmbH & Co. Main control functions of CIROS® Advanced Mechatronics Additional information I/O connections are connections between the inputs and outputs of the regarding the I/O system. but are not fully displayed. PLC outputs. for example the signal for a valve coil. connections Differentiation should be made between PLC inputs and outputs on the controller side.

but with output not displayed Connected with displayed output Inverted connection with one displayed output Forced to the value 0 Process outputs Not connected Connected. but with input not displayed Connected with one or several displayed outputs Important You may only delete those I/O connections. Main control functions of CIROS® Advanced Mechatronics Symbol Meaning Process inputs Not connected Connected. which you have created yourself as communication links. KG „ 572761 . 162 © Festo Didactic GmbH & Co. Otherwise it may no longer be possible to simulate the system correctly.4.

KG „ 572761 163 . The example selected shows an MPS Standard system. Make sure that the desired system is loaded. Main control functions of CIROS® Advanced Mechatronics This is how you open the Manual Operation window 1. which is made up of the distributing. testing and sorting stations.4. © Festo Didactic GmbH & Co.

Alternatively. KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics 2. 164 © Festo Didactic GmbH & Co. Activate Manual Operation in the Modeling menu.4. open the window by activating Manual Operation under Workspaces in the Windows menu.

The example shows the process statuses and process activities for the distributing station. activate or deactivate the Show I/O Connections command in the context-sensitive menu via the right mouse button. To do so. Main control functions of CIROS® Advanced Mechatronics 3. Now double click the + symbol of those stations whose process statuses and process activities you want to monitor or control. KG „ 572761 165 . Note You can show or hide the middle section of the Manual Operation window headed I/O Connections as required. © Festo Didactic GmbH & Co.4.

2. then reconnected the system with controller of the stations again. Or you can „simulate“ communication signals of neighbouring stations and therefore test and commission individual PLC programs. Make sure that simulation is stopped. KG „ 572761 . we recommend that you disconnect the respective stations of the system from their controllers. 1. 166 © Festo Didactic GmbH & Co. This enables you to correct faulty process signals so that the sequence of a process continues to be executed. In this way only the commands triggered via manual operation will be executed. If you want to terminate manual operation and the respective station or selected stations are to be controlled via the PLC programs again. This procedure prevents the output of conflicting commands to process components. You may however also want or need to intervene manually in the running of a station controlled via a PLC program.4. The PLC programs are no longer active. Open the Manual Operation window by activating Manual Operation in the Modeling menu. Main control functions of CIROS® Advanced Mechatronics This is how you control individual actuators of a system If you want to manually actuate individual actuators of a system or selectively set communication signals.

highlight the required station in the Process Activity section of the Manual Operation window. Disconnect the system from the controllers. KG „ 572761 167 . Main control functions of CIROS® Advanced Mechatronics 3. To do so. Note You can of course also disconnect the controller from just one station. Move the mouse pointer into the left section of the Manual Operation window to the process activities.4. Press the right mouse button to open a context-sensitive menu and select the Disconnect All Controllers command. © Festo Didactic GmbH & Co. Then open the context-sensitive menu via the right mouse button and select the Disconnect Selected Controllers command.

5. Double click the line of the process activity you wish to execute.4. this is set to 1 and vice versa. If the value 0 applies. KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics 4. 168 © Festo Didactic GmbH & Co. The double click therefore has a toggle function. Please note: To switch a valve with two valve coils into a specific switching position. The double click causes the value of the signal to change. then the value of the corresponding valve coil changes. 6. the appropriate signal must be applied at both valve coils. If you double click a line with a valve actuation. Start the simulation. Stop the simulation if you wish to terminate manual operation.

Main control functions of CIROS® Advanced Mechatronics 7. Notes The execution of the Reset Workcell command in the Simulation menu also causes the inputs/outputs of the system to be reconnected to the inputs/outputs of the controllers. © Festo Didactic GmbH & Co.4. KG „ 572761 169 . Open the context- sensitive menu via the right mouse button and select the Restore I/O Connections command. To control the system via the PLC programs in the controllers again. move the mouse pointer into the left section of the Manual Operation window to the Process Activities.

1. 170 © Festo Didactic GmbH & Co.4. KG „ 572761 . then you need to set stops within the simulation of the system. the system simulation stops if the signal value changes. Main control functions of CIROS® Advanced Mechatronics This is how you set the stops in the operation of a system If you want to stop the operation of a system at a defined point. Make sure that the desired system is loaded. The stops merely influence the simulation of the system. The changed signal value is transmitted to the system as soon as simulation is restarted. If a stop is applied to a signal. You can stop the execution of a process whenever the value of a process signal changes. the PLC programs for the control of the system remain unaffected.

Start the system simulation and make sure that the system is controlled via the PLC programs. © Festo Didactic GmbH & Co. Open the Controller Selection window if the system is controlled via the sample PLC programs of the individual stations. click onto the Controller Selection command in the Programming menu. Main control functions of CIROS® Advanced Mechatronics 2. By the symbol of the green arrowhead in the Start/Stop column you will see that all three controllers of the system shown are operating and the PLC programs are being executed in the controllers. To do so.4. KG „ 572761 171 .

Open the Manual Operation window by activating Manual Operation in the Modeling menu. Main control functions of CIROS® Advanced Mechatronics 3. If the window is in three parts. 172 © Festo Didactic GmbH & Co. deactivate the Show I/O Connections command in the context-sensitive menu via the right mouse button. you can hide the middle I/O Connections section since this section is not required when working with stops. KG „ 572761 .4. To hide the I/O Connections window section.

Double click the + symbol for the-example of the distributing station to display all the process activities of this station.4. to control the valve coil 1M1 for the ejector slide of the magazine. in the case of this example line 2. Press the right mouse button to open the context- sensitive menu and select Stop at Value Change. Now click onto the line of the required process activity. KG „ 572761 173 . Main control functions of CIROS® Advanced Mechatronics 4. © Festo Didactic GmbH & Co.

4. KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics 5. 174 © Festo Didactic GmbH & Co. The stop symbol in the line in the Manual Operation window indicates that a stop is set at this signal.

© Festo Didactic GmbH & Co. Main control functions of CIROS® Advanced Mechatronics 6. The process is continued if you restart simulation of the system. As soon as the PLC of the distributing station generates a 1 signal at valve coil 1M1.4. You can follow the status of simulation at the status bar. 7. The ejecting slide of the magazine ejects a workpiece. Operate the process. KG „ 572761 175 . simulation stops.

4. Main control functions of CIROS® Advanced Mechatronics

8. If you want to delete the stop, click onto the line with the stop point
with the right mouse button. Open the context-sensitive menu via
the right mouse button and select the command Stop at Value
Change. This command is realised in the form of a toggle function.
The stop is removed. Alternatively you can also select the Delete All
Stops command.

Note that you can also set stop at the signals in the Process Status
section of the window.

176 © Festo Didactic GmbH & Co. KG „ 572761

4. Main control functions of CIROS® Advanced Mechatronics

This is how you control the operation of a system step by step

Use the Manual Operation window as a tool to control the simulation if
you want to execute the sequence of the process step by step. You can
stop the process at defined points by setting stops.
To execute the process step by step, set the stops at the process
activities of a station or of several stations. With this procedure the
process is stopped whenever an actuator of the respective station
changes its status. If you also want to take into consideration and
monitor communication signal during the step by step operation, then
you need to set the stops at the corresponding signals in the window
section Process Activity and Process Status.

1. Make sure that the required system is loaded. It is generally helpful
if the system is in the initial position.

© Festo Didactic GmbH & Co. KG „ 572761 177

4. Main control functions of CIROS® Advanced Mechatronics

2. Start simulation of the system and make sure that the system is
controlled via PLC programs. You can establish the operational
status of the individual controllers in the Controller Selection
window.

3. Open the Manual Operation window by activating Manual
Operation in the Modeling menu.
4. If the I/O connections are displayed in the Manual Operation
window, then hide these.

178 © Festo Didactic GmbH & Co. KG „ 572761

4. Main control functions of CIROS® Advanced Mechatronics

5. Double click the + symbol, for example of the distributing station, to
display all the process activities of this station.
Under Process Activity , highlight all lines which contain signals for
valve coils by pressing the Ctrl key and clicking onto the desired
lines with the left mouse button.
Open the context-sensitive menu via the right mouse button and
select Stop at Value Change.

© Festo Didactic GmbH & Co. KG „ 572761 179

4. Main control functions of CIROS® Advanced Mechatronics

6. All lines with valve coils now show stops.

180 © Festo Didactic GmbH & Co. KG „ 572761

4. Main control functions of CIROS® Advanced Mechatronics

7. If you also want to monitor communication, then you need to
similarly set stops at the corresponding communication signals.
In the case of MPS Standard systems, the communication exchange
takes place via optical sensors. For the distributing station only the
optical sensor IP_FI needs to be considered.

8. Operate the process using the pushbuttons and switches of the
station control consoles. The simulation stops whenever the status
of a process signal of the distributing station changes. The process
continues to be executed when you restart the simulation.

© Festo Didactic GmbH & Co. KG „ 572761 181

doing so for both window sections. Open the context-sensitive menu via the right mouse button if you want to remove the stops again. KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics 9.4. Select the Delete All Stops entry. 182 © Festo Didactic GmbH & Co.

4. the sample PLC program is automatically loaded to the internal PLC of the respective station. you need to keep in mind the following: Only complete project files with the file extension S7P can be loaded. STL or GRAPH. The S7 simulator interprets executable S7 using the internal S7 PLC programs. A SIMATIC S7 simulator is Controlling a system used as internal PLC. You can of course also download a different S7 program to the internal PLC of a station. Once simulation of the system is started the internal PLC executes the S program. When you load a station from the library. © Festo Didactic GmbH & Co. A sample PLC program for S7-300 is available for each station. Main control functions of CIROS® Advanced Mechatronics 4. KG „ 572761 183 . FCH. This is the case with all STEP-7 programs created in LDR. The projects must have been created with the SIMATIC Manager and conform to the Siemens MC7 code at the binary level.10 Each station is equipped with an internal PLC. If doing so.

KG „ 572761 . Load the desired MPS system. the PLC programs of the individual stations are also executed.4. The supplied sample PLC program for each station is loaded by default to the corresponding internal PLC. testing and sorting stations. Activate Start command in the Simulation menu. As soon as simulation of the system is started. The system is made up of the distributing. The sample selected displays an MPS Standard system. 3. Main control functions of CIROS® Advanced Mechatronics This is how you control a station using a corresponding sample PLC program 1. 184 © Festo Didactic GmbH & Co. 2.

© Festo Didactic GmbH & Co. KG „ 572761 185 . Load the desired MPS station. Main control functions of CIROS® Advanced Mechatronics Note If you have modified the PLC program for a station in the corresponding internal PLC. Make sure that simulation is stopped.4. This is how you control a station using a newly created S7 PLC program 1. the modified PLC program will of course be executed once simulation is started. 2.

KG „ 572761 . 186 © Festo Didactic GmbH & Co. Select the Open command in the File menu to open the Open File window. The PLC program is to be executed by the internal PLC. Select the station whose PLC program you want to modify. To do so. activate the Controller Selection command in the Programming menu. In the Controller Selection window click on to the required station in the Currentcolumn. 4.4. Main control functions of CIROS® Advanced Mechatronics 3.

All the files of this format available in the active directory are displayed. Navigate to the directory which contains your S7 project. Main control functions of CIROS® Advanced Mechatronics 5. KG „ 572761 187 . © Festo Didactic GmbH & Co. Select the required S7 project and click onto Open.S7P). Under file type.4. 6. select S7 Project (*.

4. Main control functions of CIROS® Advanced Mechatronics

7. If the project you have selected contains several S7 programs, select
the one required for the simulation and confirm this with OK.

8. Start simulation of the system. Select the Start command in the
Simulation menu. Once simulation of the system starts the PLC
programs of the individual stations are also started. The newly
loaded PLC program of the internal PLC is executed for the station
you have selected.

Note Another option is also available for loading PLC programs to the internal
PLC of station.

188 © Festo Didactic GmbH & Co. KG „ 572761

4. Main control functions of CIROS® Advanced Mechatronics

This is how you load a PLC program to an internal PLC (alternative
method)

1. Make sure that the desired MPS system is loaded.

2. Make sure that simulation is stopped.
3. Open the S7 Program Manager by activating the S7 Program
Manager command in the Programming menu.

© Festo Didactic GmbH & Co. KG „ 572761 189

4. Main control functions of CIROS® Advanced Mechatronics

4. The just loaded PLC program for each internal PLC is shown in a
clearly set out tree structure.
Click onto the + symbol in front of the station whose PLC program
you want to change. In the exampIe the testing station has been
selected. Highlight the Program entry.

190 © Festo Didactic GmbH & Co. KG „ 572761

4. Main control functions of CIROS® Advanced Mechatronics

5. Open the context-sensitive menu via the right mouse button and
select the Load command.

6. The Open window is now displayed.

© Festo Didactic GmbH & Co. KG „ 572761 191

4. Main control functions of CIROS® Advanced Mechatronics

7. Navigate to the directory which contains your S7 project.
Select the desired S7 project and click onto the Open button.

8. If the project you have selected contains several S7 programs, select
the one required for simulation. Confirm your selection with OK.

The required PLC program is loaded. You can now simulate the
operation of the system.

192 © Festo Didactic GmbH & Co. KG „ 572761

4. Main control functions of CIROS® Advanced Mechatronics

This is how you establish which S7 program in the internal PLC of a
station has just been loaded

1. Make sure that the desired MPS system is loaded.

2. Activate the S7 Program Manager command in the Programming
menu.

© Festo Didactic GmbH & Co. KG „ 572761 193

functions and system functions. The PLC program can consist of the following modules: Organisation modules. 4.4. 194 © Festo Didactic GmbH & Co. KG „ 572761 . data modules. Click onto the + symbol to display the name and structure of the PLC program. Main control functions of CIROS® Advanced Mechatronics 3. A clearly set out tree structure shows the just loaded PLC program for each internal PLC.

You can view the contents of the module by double clicking onto a module. Further information regarding the display of S7 programs in STL or the display and use of timing diagrams can be found in the online Help. Main control functions of CIROS® Advanced Mechatronics 5. © Festo Didactic GmbH & Co.4. Click onto the + symbol again to display the modules of the PLC programs. KG „ 572761 195 .

KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics This is how the sample PLC programs are filed on the computer 1. All the files of this format available in the active directory are displayed. Select the Open command in the File menu. 2. The Open File window is now displayed.4. Select S7 Project (*. 196 © Festo Didactic GmbH & Co.S7P) under file type.

Navigate into the directory in which you have installed the Software package CIROS® Advanced Mechatronics software package.s7p. ‟ The directory Store contains the sample PLC programs for the automated warehouse station. As an example. 4. KG „ 572761 197 .4. change to the directory MPSC_V22. © Festo Didactic GmbH & Co. where you will find the sample PLC programs for all MPS Standard stations. From there change to the directory \CIROS® Advanced Mechatronics\bin\FD_PLC_ADV\S7 where four subdirectories are shown. ‟ The directory MPSC_V22 contains the S7 project mpsc_v22. ‟ The directory 313C__1 contains the sample PLC programs for the individual stations of MPS 500-FMS systems. Select the S7 project and click onto Open. Main control functions of CIROS® Advanced Mechatronics 3. ‟ The directory FMS50__1 contains the sample PLC programs for the transport system of MPS 500-FMS systems.

KG „ 572761 . KFA: The programming languages LDR. function chart. FCH and STL. Main control functions of CIROS® Advanced Mechatronics The program name provides information about the PLC program and the station model to which it belongs: The initial digit corresponds to the station number. The internal PLC supports to a large extent the command set of the S7- 400 controllers. statement list or in the form of graphic sequence control. The two letters after the first digit indicate the station: VE: Distributing station PR: Testing station BE: Processing station HA: Handling station PU: Buffer station MO: Assembly station SO: Sorting station PP: Pick&Place station FM: Fluidic Muscle Press station TR: Separating station LA: Storage station The letters starting with underscore indicate the programming language of the PLC program: AS: The programming language GRAPH. whereby the programs can be created in ladder diagram.4. 198 © Festo Didactic GmbH & Co.

Main control functions of CIROS® Advanced Mechatronics 5. The EzOPC program forms part of the CIROS® Automation Suite and has been installed on your PC together with the CIROS® Advanced Mechatronics application.4. then install these a second time using the specially provided installation command of CIROS® Advanced Mechatronics Assistant. You can use these functions if you create the PLC program for a station of a system in STEP-7 and then test the PLC program in conjunction with the simulation of the system. EzOPC is automatically invoked by CIROS® Advanced Mechatronics as soon as you start simulation of the system. © Festo Didactic GmbH & Co. please make sure that the used S7-PLCSIM-Version is Vista compatible.11 S7-PLCSIM is a soft PLC. Close the window by clicking on the Cancel button. Note You must never modify the sample PLC programs shown here because these are the standard default programs required for the simulation of an MPS system. These Soft PLC S7-PLCSIM testing and diagnostic functions include for example the status display of variables or the online display of the PLC program. which executes the PLC programs created in Controlling a system STEP 7. If you want to make changes to the PLC programs. Note If you work with the operating system Vista. A wide range of different testing and diagnostic functions for station using the external fault finding in the PLC program are available within STEP 7. 4. KG „ 572761 199 . The exchange of PLC input/output signals between the system and the soft PLC S7-PLCSIM is effected via the EzOPC program. The prerequisite for starting EzOPC is of course that at least one station of the system is controlled via an external PLC.

The EzOPC program must be correctly configured for the exchange of data. Only then can EzOPC set up the communication link to both users. the following requirements must be met: When starting EzOPC. Configuration of EzOPC for data exchange with S7-PLCSIM 200 © Festo Didactic GmbH & Co. Therefore check the configuration as soon as EzOPC is started. KG „ 572761 .4. Main control functions of CIROS® Advanced Mechatronics To ensure that the exchange of PLC input/output signals with the selected station is correctly effected. both communication users – S7-PLCSIM and simulation of the system – must be active.

Main control functions of CIROS® Advanced Mechatronics This is how you control a station of the virtual system using S7- PLCSIM 1. KG „ 572761 201 . Start S7-PLCSIM by clicking onto the menu item Simulate Modules under Extras. Start STEP 7 or then STEP 7 Manager and open the desired S7 project. 2. © Festo Didactic GmbH & Co.4.

4. Enter the input/output bytes you want to exchange and monitor. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto MRES in the CPU window. 4. Main control functions of CIROS® Advanced Mechatronics 3. 202 © Festo Didactic GmbH & Co. KG „ 572761 . The window of S7-PLCSIM is opened.

4. The PLC program is to control a selected station in a virtual MPS system in CIROS® Advanced Mechatronics. The selected station to be controlled via S7-PLCSIM is the distributing station. Main control functions of CIROS® Advanced Mechatronics 5. Download the required PLC program to the S7-PLCSIM by highlighting the modules folder. © Festo Didactic GmbH & Co. Then activate the Download command in the PLC menu. KG „ 572761 203 .

Load the appropriate MPS system in CIROS® Advanced Mechatronics. Make the necessary setting for the desired station. i.4. 204 © Festo Didactic GmbH & Co. KG „ 572761 .e. Main control functions of CIROS® Advanced Mechatronics 6. 7. that this is to be controlled via an external PLC by activating the Switch external PLC internal PLC command in the Modeling menu.

KG „ 572761 205 .4. Main control functions of CIROS® Advanced Mechatronics 8. Highlight the desired station via mouse click. © Festo Didactic GmbH & Co. Activate the context- sensitive menu via the right mouse button and select the Switch command.S7P with specified path. ‟ The station is controlled via the internal PLC. 9. You can establish this by the S7 PLC simulator entry. As an example consider the entries for the distributing station: ‟ The name of the station is Distributing. ‟ The internal PLC executes a PLC program. Alternatively changeover the controller by double clicking the desired station. The Switch external PLC internal PLC window is now opened. which is part of the STEP 7 project MPSC_V22. The columns Type and Program Name/OPC Server show the information for the controller of the selected station.

EzOPC. For the selected station OPC server is now entered in the Type column. 206 © Festo Didactic GmbH & Co.2 is now displayed under program name/OPC server. KG „ 572761 . The name FestoDidactic.2. 11. Check whether the system should be in the initial position. Close the Switch external PLC internal PLC window. activate Reset Workcell command in the Simulation menu. Main control functions of CIROS® Advanced Mechatronics 10.4. This entry means the process signals for the selected station are exchanged via an OPC server named FestoDidactic. If so. 12.EzOPC.

4. Main control functions of CIROS® Advanced Mechatronics 13. © Festo Didactic GmbH & Co. KG „ 572761 207 . You can establish this by the EzOPC entry in the bar. When simulation is started the EzOPC progam is automatically invoked. Start simulation of the system by activating Start in the Simulation menu.

Click onto EzOPC in the start bar. 208 © Festo Didactic GmbH & Co. The overview indicates that CIROS® Advanced Mechatronics is connected to S7 PLCSim via the virtual controller of EzOPC. The desired communication links are established by clicking onto the appropriate button.4. Main control functions of CIROS® Advanced Mechatronics Note With the starting of system simulation. the communication program EzOPC is also started. both communication users . The table shows which components are installed individually and whether EzOPC is in the process of accessing this component. 14. The EzOPC window is now displayed. When EzOPC is started. Make sure that the communication links of your EzOPC are configured as shown below.S7-PLCSIM and the simulation of the system – must already be active. KG „ 572761 . where you configure the communication between CIROS® Advanced Mechatronics and S7-PLCSIM. Only then are the communication links correctly set up.

If a 1-signal is applied to an input/output byte bit. © Festo Didactic GmbH & Co. then this is shown illuminated. Now click onto the Virtual Controller register where the virtual controller status and your inputs/outputs are displayed. KG „ 572761 209 .4. Main control functions of CIROS® Advanced Mechatronics 15. You can accept this presetting unaltered. 8 input bytes and 8 output bytes are preset for data exchange.

If a 1-signal is applied to an input/output byte bit. then this is shown illuminated. Main control functions of CIROS® Advanced Mechatronics 16. 210 © Festo Didactic GmbH & Co. You can accept this presetting unaltered. Here. 8 input bytes and 8 output bytes are preset for data exchange. 17. However. KG „ 572761 .4. the status of S7-PLCSim simulation and its inputs/outputs is displayed. only the first 4 bytes are required. Click onto the S7-PLCSIM register and check the settings. Minimise the EzOPC window.

KG „ 572761 211 . Main control functions of CIROS® Advanced Mechatronics 18. Start S7-PLCSIM by clicking onto the check box next to RUN in the CPU window. © Festo Didactic GmbH & Co.4. The LED for RUN should now start flashing.

Main control functions of CIROS® Advanced Mechatronics 19. 212 © Festo Didactic GmbH & Co. In particular. It can be useful here to monitor the statuses of the PLC inputs and outputs for the respective station. observe the behaviour of those stations for which you have created the PLC program yourself. Open the Inputs and Outputs window by activating the commands Show Inputs or Show Outputs under the Inputs/Outputs entry in the View menu. Operate the system.4. KG „ 572761 .

Select the controller for the desired station in the Current column.4. Main control functions of CIROS® Advanced Mechatronics 20. © Festo Didactic GmbH & Co. KG „ 572761 213 . For the example this should be the distributing station. Make sure that the PLC inputs and outputs for the right station are displayed by activating the Controller Selection command in the Programming menu.

call up the program module in which you suspect the fault.4. Activate the Monitor command in the Test menu. Main control functions of CIROS® Advanced Mechatronics 21. then the online representation in STEP 7 provides excellent support during fault finding. KG „ 572761 . To do so. If errors still exist in the PLC program. 214 © Festo Didactic GmbH & Co. You can now monitor which PLC program sections are executed or not in parallel with the simulation of the process.

KG „ 572761 215 .12 CoDeSys SP PLCWinNT is a Soft PLC which executes the PLC programs Controlling a station of created in CoDeSys. and will have been installed on your PC together with the CIROS® Advanced Mechatronics application. EzOPC is part of the CIROS® Automation Suite. the system using the external Soft PLC The PLC input and output signals are exchanged between the system CoDeSys SP PLCWinNT simulation and the Soft PLC CoDeSys SP PLCWinNT via the EzOPC program. Of course. © Festo Didactic GmbH & Co. ensure that the version of CoDeSys SP PLCWinNT which you are using is Vista- compatible. at least one station of the system must be under the control of an external PLC before EzOPC can be started. Note If you are using the MS Windows Vista operating system. CIROS® Advanced Mechatronics automatically starts up EzOPC as soon as the simulation of the system begins. Main control functions of CIROS® Advanced Mechatronics 4.4.

4. KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics The following requirements must be fulfilled in order to ensure that the PLC input and output signals are exchanged correctly with the selected station: There must be an interface to the OPC server EzOPC in the CoDeSys PLC program. The input and output signals of the PLC program are transferred byte by byte via this interface. The UNPACK functional module and the PACK function in CoDeSys can be used to convert bits to bytes. Program execution in CoDeSys SP PLCWinNT UNPACK (FB) PLC program PACK (FUN) EB0 OPC_notUsed OPC_notUsed AB1 B B0 B0 PACK OPC_1B2 OPC_P2 B1 OPC_1B2 & OPC_P2 B1 OPC_notUsed OPC_notUsed B2 OPC_2B1 B2 OPC_2B1 OPC_notUsed B3 OPC_3B1 B3 OPC_3B1 OPC_notUsed B4 B4 OPC_notUsed OPC_notUsed B5 B5 OPC_notUsed OPC_notUsed B6 B6 OPC_notUsed OPC_notUsed B7 B7 EzOPC Process inputs Process outputs (Sensors) (Actors) CIROS® Process model simulation Simple program example of OPC interface in CoDeSys 216 © Festo Didactic GmbH & Co.

Configuration of EzOPC for data exchange with S7-PLCSIM © Festo Didactic GmbH & Co. Main control functions of CIROS® Advanced Mechatronics When starting EzOPC.4. check the configuration as soon as EzOPC starts up. both communication users – CoDeSys SP PLCWinNT and the system simulation in CIROS – must already be active. In order to ensure this. Only then can EzOPC set up the communication link to both users. KG „ 572761 217 . The EzOPC program must be correctly configured for data exchange.

Main control functions of CIROS® Advanced Mechatronics This is how you control a station of the virtual system with CoDeSys SP PLCWinNT 1. Start CoDeSys and open the desired CoDeSys project. 218 © Festo Didactic GmbH & Co.4. KG „ 572761 .

The input/output signals are defined as global variables. then double-clicking on Global_Variables. add the Util. define the input/output signals to be exchanged with the CIROS® process model via the OPC interface. You can open the Global_Variables window by opening the Global Variables folder in the Resources tab.lib library is entered in the Resources tab. Close the Library Manager window. In the Insert menu. click on the Open button. © Festo Didactic GmbH & Co. Once you have selected the Util.lib library using the Library Manager: Double-click on Library Manager in the Resources tab. Main control functions of CIROS® Advanced Mechatronics 2. Make sure that the Util.lib library. KG „ 572761 219 . 3. The input/output signals in the example project can be easily identified by the extension OPC. Next. If this is not the case.4. select Additional Library. The default location for the library is in the directory c:\Program Files\3S Software\CoDeSys\Library. Find the location where Util.lib is stored.

KG „ 572761 . the PACK function shows the output signal OPC_P2 on bit 1 of output byte AB1. Remember that an instance (Unpack_EB0 in the example) must be defined in the program head before a functional module can be called up. 220 © Festo Didactic GmbH & Co. Main control functions of CIROS® Advanced Mechatronics 4. In the example. This extracts the EB0 input byte and converts it into 8 Boolean variables. The PACK function combines 8 Boolean variables into one byte. 3 and 4 of the EB0 input byte are needed. 5.4. Expand the control program by calling up the UNPACK functional module. only bits 1. Expand the control program by calling up the PACK function. In the example project.

4. Main control functions of CIROS® Advanced Mechatronics 6. configure the settings in CoDeSys for the data exchange between CoDeSys SP PLCWinNT and CIROS® Advanced Mechatronics. KG „ 572761 221 . go to 3S Software -> Communication and select CoDeSys OPC Configurator. To do this. open the Start menu. 3S CoDeSys SP PLCWinNT must be set as the configuration. Next. © Festo Didactic GmbH & Co. To do this. Make sure that the Soft PLC CoDeSys SP PLCWinNT is set as the target system for the project. 7. double-click on Target Settings in the Resources tab.

In the tree structure. KG „ 572761 . click on Server and set an Update Rate of 100 for the OPC server. you can also use the preset value. 222 © Festo Didactic GmbH & Co.4. Alternatively. 9. Main control functions of CIROS® Advanced Mechatronics 8. Set Single PLC for OPC communication. Do this by selecting Single PLC in the File menu.

KG „ 572761 223 . In the tree structure. Main control functions of CIROS® Advanced Mechatronics 10. Note The project name must exactly match the name of the CoDeSys project file. the name must also be changed here to match. click on PLC and enter the name of the PLC project.4. © Festo Didactic GmbH & Co. If the project is changed.

Configure the settings in the Communication Parameters window. As both programs run on the same computer. click on Connection to specify the type of connection between the OPC server and the Soft PLC. Select Tcp/lp with the Address localhost as the Device for the new connection. Open the Communication Parameters window by clicking on the Edit button. select the Local option for Gateway. 224 © Festo Didactic GmbH & Co. KG „ 572761 .4. Main control functions of CIROS® Advanced Mechatronics 11. In the tree structure. Then click on the Gateway button and select Local as the connection for Gateway. 12.

14. KG „ 572761 225 .4. Close the window Communication Parameters: New Channel. Enter the name of the channel and select Tcp/lp as the device. Click the New button to define the parameters for the new connection channel. Close the windows Communication Parameters and OPCConfig. © Festo Didactic GmbH & Co. 15. Main control functions of CIROS® Advanced Mechatronics 13.

activate the Options command in the Project menu in CoDeSys. Main control functions of CIROS® Advanced Mechatronics 16. KG „ 572761 . To do this. 226 © Festo Didactic GmbH & Co. click on Symbol configuration. Next. prepare the input/output bytes which are to be transferred via the OPC interface for data exchange.4. In the Options window.

4. Main control functions of CIROS® Advanced Mechatronics 17. KG „ 572761 227 . Select Dump symbol entries. This opens the Set object attributes window. then click on the configure symbol file button. © Festo Didactic GmbH & Co.

20. Hold down the Ctrl key while selecting. KG „ 572761 . Open the Global Variables folder and select the objects AB1 (BYTE) and EB0 (BYTE). Place a tick in each check box and close the Set object attributes and Options windows. Main control functions of CIROS® Advanced Mechatronics 18. 19. Click on the Rebuild all command in the Project menu. 228 © Festo Didactic GmbH & Co. Start CoDeSys SP PLCWinNT by selecting it from the Start menu.4.

The CoDeSys SP PLCWinNT window opens. activate the Login command in the Online menu in CoDeSys. Main control functions of CIROS® Advanced Mechatronics 21. KG „ 572761 229 . © Festo Didactic GmbH & Co. To establish the connection between the CoDeSys programming system and the Soft PLC CoDeSys SP PLCWinNT. 22.4.

230 © Festo Didactic GmbH & Co.4. If the current project is different to the PLC program in the Soft PLC. KG „ 572761 . Click Yes. The current project is loaded into the Soft PLC. you will be asked whether you wish to load the current PLC program when you log in. Main control functions of CIROS® Advanced Mechatronics 23.

Alter the settings for the desired station so it is controlled by an external PLC. © Festo Didactic GmbH & Co.4. 25. To do this. Main control functions of CIROS® Advanced Mechatronics 24. go to the Modeling menu and activate the Switch external PLC internal PLC command. Load the corresponding MPS in CIROS® Mechatronics. KG „ 572761 231 .

The PLC program is part of the STEP 7 project MPSC_V22. take a look at the entries for the Distributing station: ‟ The name of the station is S7_Distributing. For example. Click the right mouse mutton to open the context-sensitive menu. 232 © Festo Didactic GmbH & Co. you can switch the control system by double-clicking on the desired station. Select the Switch command. Main control functions of CIROS® Advanced Mechatronics 26.S7P with the specified path. The Switch external PLC internal PLC window opens. KG „ 572761 . You can see this from the S7 PLC Simulator entry in the Type column. The Type and Program Name/OPC Server columns show information on how the selected station is controlled. ‟ The internal PLC executes a PLC program. 27. ‟ The station is controlled by the internal PLC. Alternatively.4. Click on the desired station to highlight it.

EzOPC. 29. The column Type now shows OPC Server for the selected station. This means that the process signals for the selected station are exchanged via an OPC server with the name FestoDidactic. 30. KG „ 572761 233 . The Program Name/OPC Server column now shows the server name FestoDidactic. If so.2.4. © Festo Didactic GmbH & Co. Check whether the system is meant to be in the basic setting.2. Main control functions of CIROS® Advanced Mechatronics 28. activate the Reset Workcell order in the Simulation menu.EzOPC. Close the Switch external PLC internal PLC window.

Note When the system simulation starts. Only if this is the case will the communication links be correctly set up. To do this. Start the simulation of the system. the EzOPC program is automatically opened. As the simulation starts. When starting EzOPC. Main control functions of CIROS® Advanced Mechatronics 31. KG „ 572761 . open the Simulation menu and select Start.4. the EzOPC communication program also starts up. You can see this because EzOPC appears in the start bar. both communication users – CoDeSys SP PLCWinNT and the system simulation – must already be active. 234 © Festo Didactic GmbH & Co.

© Festo Didactic GmbH & Co. The table shows details of which components are installed whether EzOPC directly accesses these components. Click on the EzOPC button in the Start bar. The overview shows that CIROS® Advanced Mechatronics is connected to CoDeSys SP PLCWinNT via the EzOPC virtual control system. The EzOPC window opens. Main control functions of CIROS® Advanced Mechatronics 32. You can create the desired communication link by clicking the corresponding button. Here you can configure the communication between CIROS® Advanced Mechatronics and CoDeSys SP PLCWinNT. Make sure that the communication links of your EzOPC are configured as shown below. KG „ 572761 235 .4.

236 © Festo Didactic GmbH & Co. click on the Virtual Controller tab. 8 input bytes and 8 output bytes are preset for data exchange. You can use this preset without modifying it. Next. KG „ 572761 . If logic 1 applies to any bit of the input/output byte. This displays the status of the virtual controller and its I/Os.4. Main control functions of CIROS® Advanced Mechatronics 33. this bit is represented by a brighter colour.

Main control functions of CIROS® Advanced Mechatronics 34. KG „ 572761 237 . 8 input bytes and 8 output bytes are preset for data exchange. However. This tab shows the status of the CoDeSys SP PLCWinNT simulation and its inputs/ outputs. 36. © Festo Didactic GmbH & Co. Make sure that the process model simulation is active in CIROS® Advanced Mechatronics. Minimise the EzOPC window. 35. this bit is represented by a brighter colour. Click on the CoDeSys tab and check the settings. only the first 4 bytes are required. You can use this preset without modifying it.4. If logic 1 applies to any bit of the input/output byte.

open the Online menu and click Run. Start running the PLC program in the Soft PLC.4. Main control functions of CIROS® Advanced Mechatronics 37. You can see the current status of the Soft PLC CoDeSys SP PLCWinNT in the CoDeSys SP PLCWinNT window. 238 © Festo Didactic GmbH & Co. To do this. KG „ 572761 .

You might find it helpful to follow the statuses of the PLC inputs and outputs for the station in question. KG „ 572761 239 . Pay particular attention to the behaviour of the station to which you have added the PLC program yourself. go to the View menu. Operate the system. Main control functions of CIROS® Advanced Mechatronics 38. select Inputs/Outputs and activate the Show Inputs and Show Outputs commands.4. © Festo Didactic GmbH & Co. To open the Inputs and Outputs windows.

To do this. KG „ 572761 . go to the Programming menu and activate the Controller selection command. Select the control system for the desired station in the Current column. this would be the Distributing station. In the example.4. Make sure that the PLC inputs and outputs are shown to the right station. Main control functions of CIROS® Advanced Mechatronics 39. 240 © Festo Didactic GmbH & Co.

© Festo Didactic GmbH & Co. You can however also use any other control and programming system.4. We recommend that you install the simulation software CIROS® Advanced Mechatronics and the PLC programming system on different computers. Also the testing and diagnostic functions provided by the programming system for this purpose are available to you for fault finding in the PLC program. The advantage of this configuration is that you can use the PLC and the programming system of your choice. in which case you will not require any additional hardware components. external PLC If you are programming in STEP 7.13 If you are creating and testing your own PLC programs we recommend Controlling a station of that you load the programs to an external PLC and execute them from the system using an there. in which case you load the PLC program to your hardware PLC. KG „ 572761 241 . The exchange of PLC input/output signals between the system simulation and your external PLC is effected via the serial or the USB interface of the PC and via the EasyPort interface. In addition the EzOPC program is involved in the exchange of process signals. The PLC program is to control a selected station of your virtual system. you can use the soft PLC S7-PLCSIM as PLC. Main control functions of CIROS® Advanced Mechatronics 4.

KG „ 572761 .4. Main control functions of CIROS® Advanced Mechatronics Station of a system PLC programming system STEP7 EasyPort PLC Possible configuration with hardware PLC and two PCs 242 © Festo Didactic GmbH & Co.

167 197) For any PLC: I/O data cable with SysLink connector to IEEE 488 at one end and open cable end sleeves (Pt. KG „ 572761 243 . 540699) For PLC EduTrainer from Festo Didactic: I/O data cable with SysLink connectors to IEEE 488 at both ends (Pt. EzOPC does not access the signals of the external PLC directly but via the EasyPort interface. Prerequisite for starting EzOPC is of course that at least one station of the system is controlled via an external PLC. crossover (Pt. Your PC needs to be equipped with two serial interfaces or one serial and one USB interfaces if you want to use the testing and diagnostic functions of the programming system during simulation of the virtual system. You can use the following as EasyPort interface: EasyPort D16 interface box for 16 digital I/O (Pt. 034 031) and adapter for extension to IEEE 488. The EzOPC program The EzOPC program organises the exchange of PLC input/output signals between the virtual system simulation and the external PLC. No. No.4. EzOPC is automatically invoked by CIROS® Advanced Mechatronics as soon as simulation of the system starts. you will need two or more EasyPort interfaces. No. © Festo Didactic GmbH & Co. 162305) or USB adapter RS232 for EasyPort with PC on USB (Order No. The EzOPC program forms part of the CIROS® Automation Suite and has been installed on your PC in conjunction with the CIROS® Advanced Mechatronics application. 167 122) Note If you want to exchange signals of one or more than 16 process inputs/outputs between an external PLC and a virtual system in CIROS® Advanced Mechatronics. Main control functions of CIROS® Advanced Mechatronics You can however also select another configuration and install the two software packages on one PC. 167121) The following is required as data cable: PC data cable RS232 for EasyPort with PC to RS232 (Order No. No.

The EzOPC must be correctly configured for the exchange of data. Main control functions of CIROS® Advanced Mechatronics The following requirements must be fulfilled to ensure that the exchange of PLC input/output signals with the selected station is correct: When starting EzOPC.4. Therefore check the configuration as soon as EzOPC is started. Only then can EzOPC set up the communication link with the two users. both communication users ‟ EasyPort and simulation of the system ‟ must be active. Configuration of EzOPC for data exchange with an external PLC via EasyPort 244 © Festo Didactic GmbH & Co. KG „ 572761 . In the case of EasyPort this means that EasyPort must be connected to the PC via the serial or the USB interface and voltage must be applied to EasyPort.

The external PLC is in the STOP operating status.4. then use the data cable of Order No. © Festo Didactic GmbH & Co. KG „ 572761 245 . Connect the PC with CIROS® Advanced Mechatronics to the external PLC via the EasyPort interface. No. ‟ If you are using EasyPort without USB interface: Select the following setting for the DIP switches under Mode on EasyPort: 1 ON (bottom). If you are using the USB interface. 2. Load the desired PLC program to the external PLC. ‟ The PLC input output signals for the process are applied at port 1 of EasyPort. Main control functions of CIROS® Advanced Mechatronics This is how you control a station of a virtual system using an external PLC 1. The set address can be read or changed by pressing the two arrow buttons. ‟ The PLC input/output signals for the control console are transmitted via port 2. 162 305 connects the serial interface of the PC to the serial interface RS232 of EasyPort. 2 OFF. 3 OFF. ‟ If you are using EasyPort with USB interface: Make sure that address 1 is set for EasyPort. Simultaneously pressing both buttons stores the address and exits address mode. 540699. ‟ The data cable Pt.

Main control functions of CIROS® Advanced Mechatronics Process model 1 2 3 ON S7 EduTrainer EasyPort RING IN OUT MODE RS232 . 246 © Festo Didactic GmbH & Co.4. KG „ 572761 .24V + CPU313C-2 DP CP 343-2 SF SF BF 0 0 PWR DC5V 1 1 APF FRCE 2 2 CER RUN 3 3 AUP STOP 4 4 CM PUSH 5 5 EasyPort D16 6 6 B RUN 7 7 20+ STOP MRES 10+ IN OUT SET A STATUS SHORT 9 0 0 8 1 1 7 INPUT 2 2 6 OUTPUT 3 3 5 0 7 8 15 4 4 4 5 5 3 6 6 2 7 7 1 0 PORT 1 PORT 2 B 3 1 Configuration with PLC EduTrainer Note The two sockets marked EMERGENCY-STOP must be bridged so that the output modules of the PLC receive the voltage supply.

24V + EasyPort D16 STATUS SHORT INPUT OUTPUT 0 7 8 15 PORT 1 PORT 2 XMA2 XMG1 PLC board Configuration with PLC board © Festo Didactic GmbH & Co. Main control functions of CIROS® Advanced Mechatronics Process model 1 2 3 ON EasyPort RING IN OUT MODE RS232 . KG „ 572761 247 .4.

Note that EasyPort can receive voltage supply via the PORTS. The distributing station has been selected in the example.4. Load the desired system in CIROS® Advanced Mechatronics. Switch on the voltage supply of EasyPort. One station of the system is to be controlled via an external PLC. 5. Main control functions of CIROS® Advanced Mechatronics 3. KG „ 572761 . 4. Effect the setting for the required station which is to be controlled via an external PLC by activating the Switch external PLC internal PLC command in the Modeling menu. 248 © Festo Didactic GmbH & Co.

7. KG „ 572761 249 . Main control functions of CIROS® Advanced Mechatronics 6. The controller for the selected station is shown in the columns Type and Program name/OPC Server. As an example take a look at the entries for the distributing station: ‟ The name of the station is Distributing. Alternatively changeover the controller by clicking onto the required station. Highlight the required station via a mouse click. This opens the Switch external PLC internal PLC window.4.S7P with the path indicated. ‟ The internal PLC executes the PLC program. ‟ The station is controlled via the internal PLC. You can establish this by the entry S7 SPS Simulator. © Festo Didactic GmbH & Co. Activate the context sensitive menu via the right mouse button and select the Switch command. The PLC program forms part of the STEP 7 project MPSC_V22.

activate the Reset Workcell command in the Simulation menu. This means that the process signals for the selected station are exchanged via an OPC server named FestoDidactic.2. Close the Switch external PLC internal PLC window. Check whether the system is to be in the initial position.4. 10. 9. OPC Server is entered for the selected station in the Type column. Main control functions of CIROS® Advanced Mechatronics 8.EzOPC. If so. 250 © Festo Didactic GmbH & Co. KG „ 572761 .2 is shown under Program name/OPC Server.EzOPC. FestoDidactic.

With the starting of simulation. © Festo Didactic GmbH & Co. KG „ 572761 251 . Start the system simulation by activating Start in the Simulation menu.4. Main control functions of CIROS® Advanced Mechatronics 11. the EzOPC program is automatically invoked. You can establish this by the EzOPC entry in the start bar.

12. 252 © Festo Didactic GmbH & Co. Here you configure the communication between H CIROS® Advanced Mechatronics and EasyPort. Main control functions of CIROS® Advanced Mechatronics Note With system simulation starting. both communication users – EasyPort and the simulation of the system – must already be active. Only then are the communication links correctly set up. Click onto EzOPC in the start bar to open the EzOPC window.4. When EzOPC is started. KG „ 572761 . the communication program EzOPC is also started.

KG „ 572761 253 . Main control functions of CIROS® Advanced Mechatronics 13. © Festo Didactic GmbH & Co. Click onto the PLC via EasyPort button to establish this. You will need a communication link between CIROS® Advanced Mechatronics and EasyPort. The overview shows that CIROS® Advanced Mechatronics is connected to S7 PLCSim via the virtual controller of EzOPC.4.

4. KG „ 572761 . The table indicates which components are installed and whether EzOPC is currently accessing these components. 254 © Festo Didactic GmbH & Co. Main control functions of CIROS® Advanced Mechatronics 14. The configuration link between CIROS® Advanced Mechatronics and EasyPort is configured.

Main control functions of CIROS® Advanced Mechatronics 15. Only the first 4 bytes are required. Now check the range of inputs/outputs via which data exchange is to be effected in the virtual controller. 8 input bytes and 8 output bytes are preset for data exchange. click onto the Virtual Controller register. KG „ 572761 255 .4. To do so. © Festo Didactic GmbH & Co. You can accept these presettings unaltered.

Start the PLC. 18. 19. Minimise the EzOPC window. KG „ 572761 . Click onto the EasyPort register where the status of the connected EasyPort and its inputs and outputs are displayed.4. If a 1-signal is applied to an input/output byte bit. Make sure that the required PLC program is installed in the PLC. Main control functions of CIROS® Advanced Mechatronics 16. 256 © Festo Didactic GmbH & Co. then this is shown illuminated. 17.

Open the inputs and outputs window by activating the Show Inputs/Show Outputs command under the Inputs/Outputs entry in the View menu. Main control functions of CIROS® Advanced Mechatronics 20. © Festo Didactic GmbH & Co. KG „ 572761 257 .4. Operate the system and in particular observe the behaviour of the station for which you have created the PLC program. whereby it may be helpful to observe the statuses of the PLC inputs and outputs of the relevant station.

Main control functions of CIROS® Advanced Mechatronics 21. KG „ 572761 . Make sure that the PLC inputs and outputs for the right station are displayed. 258 © Festo Didactic GmbH & Co. Activate the Controller Selection command in the Programming menu and select the controller for the desired station.4.

Use the internal S7 PLC and the sample PLC programs provided to control the system.14 Use the Fault Setting window to set specific faults in the functional Setting faults in a system sequence of a system. This ensures that any potential process malfunction is caused solely by the process components. A list of possible faults is available for each modelled system. The setting of faults is permissible for authorised persons only and the dialog for the setting of faults is therefore password protected.4. Main control functions of CIROS® Advanced Mechatronics 4. The default setting for the password is didactic. The PLC programs operate error-free. © Festo Didactic GmbH & Co. To hide the entries again double click the minus symbol. All entries for the relevant station are displayed by double clicking onto the + symbol of a station. The entries for the individual stations are arranged in a tree structure. KG „ 572761 259 . This password can be changed at any time.

Note Default malfunction however only becomes active if the fault simulation mode is activated. You can select these in a selection list. KG „ 572761 . malfunction still remains active and remains active until it is deactivated in the Fault Setting window.4. 260 © Festo Didactic GmbH & Co. Tubing faulty: Pneumatic tubing is defective. The following denote: Reed switch misaligned: Reed switch is mechanically misaligned. Reed switch stuck: A 1 signal is permanently applied at the reed switch. Compressed air line faulty: No compressed air available. The duration of malfunction is to be specified in seconds. Main control functions of CIROS® Advanced Mechatronics The following data is required if you want to create a fault in the case of one of the listed process components: Type of fault. operating pressure is not achieved. Failure: Complete component failure. If you exit and restart CIROS® Advanced Mechatronics. The error statuses are effected in the simulation of the modelled system as soon as the fault simulation is active. Duration of malfunction. Various faults can occur in the case of some components. Cable break: A 0 signal is permanently applied at the component. Short circuit: A 1 signal is permanently applied at the component. Start of malfunction. Voltage supply malfunctioning: No voltage. The time specified for the commencement of malfunction refers to the simulation period after the fault is set.

Main control functions of CIROS® Advanced Mechatronics This is how you set faults in a modelled system 1.4. Make sure that the system is loaded. © Festo Didactic GmbH & Co. The system is to be controlled via the internal PLC. KG „ 572761 261 . 2. Simulation is not active. Open the Fault Setting window by activating the Fault Setting entry in the Extras menu under Fault Simulation.

the set default password is still valid. 4. The Fault Setting window now opens. 262 © Festo Didactic GmbH & Co. enter didactic Please note that the above password is case sensitive.4. Double click the + symbol of for example the distributing station to display all the possible faults of this station. Enter the password. The dialog for the password entry is now displayed. Confirm the entry with OK. 5. Main control functions of CIROS® Advanced Mechatronics 3. KG „ 572761 . Under password. Provided that you have not changed the password since installing CIROS® Advanced Mechatronics.

No entries are therefore required in the Begin column.4. Now set a malfunction ‟ for example for the PLC input 1B1. The duration of the fault is arbitrary. No entries are therefore required in the Duration column. The fault is to become active at the start of simulation and remain active until the fault is removed from the fault setting. A selection list is displayed. for example cable break. Main control functions of CIROS® Advanced Mechatronics 6. Open this list and select the type of fault. Double click the appropriate field in the Type column. © Festo Didactic GmbH & Co. KG „ 572761 263 .

Close the file of the modelled system in order to deactivate the teacher mode. The faults selected are displayed in the Status column. 9.4. 8. Main control functions of CIROS® Advanced Mechatronics 7. 264 © Festo Didactic GmbH & Co. KG „ 572761 . Load the system with the set faults.

Main control functions of CIROS® Advanced Mechatronics 10.4. Now activate the fault simulation mode by selecting Fault Simulation in the Extras menu under Fault Simulation. © Festo Didactic GmbH & Co. KG „ 572761 265 .

KG „ 572761 . The menu item Fault Simulation in the Extras menu under Fault Simulation must be ticked. Main control functions of CIROS® Advanced Mechatronics This is how you start simulation of the system with set faults 1. 3. Make sure that the fault simulation mode is activated. 266 © Festo Didactic GmbH & Co. Load the system with the set faults. Start simulation of the system.4. 2.

moving the swivel arm into the magazine position . The sequence of the system stops once a workpiece is ejected at the distributing station.15 Use the Fault Localisation window to eliminate malfunction in the Eliminating faults in a functional sequence of the system. By observing and evaluating the system. you realise that voltage is applied at sensor 1B1 of the distributing station. but not at the corresponding PLC input. © Festo Didactic GmbH & Co. The next step . Example The MPS system viewed consists of the distributing. KG „ 572761 267 . Set malfunction only occurs if the system system is controlled via PLC programs and if the fault simulation mode is active.is not executed. Main control functions of CIROS® Advanced Mechatronics 4. You therefore conclude a cable break at the PLC input 1B1.4. testing and sorting stations.

Main control functions of CIROS® Advanced Mechatronics This is how you eliminate faults in the system 1. 2.4. Open the Fault Localisation window by clicking onto Fault Localisation in the Execute menu. 268 © Festo Didactic GmbH & Co. Make sure that the desired system is loaded. KG „ 572761 .

The Fault Localisation window is now displayed. 4. © Festo Didactic GmbH & Co. KG „ 572761 269 . Main control functions of CIROS® Advanced Mechatronics 3. Double click the + symbol of the distributing station to view all possible faults.4.

KG „ 572761 . the distributing station sequence will be executed error-free in the next simulation cycle.4. Double click no fault in the line PLC input 1B1 and select cable break from the selection list. Main control functions of CIROS® Advanced Mechatronics 5. The button is illuminated in yellow. 270 © Festo Didactic GmbH & Co. If the fault has been identified correctly.

If the cause of the fault has not been identified correctly. The fault is active as of the next simulation cycle. the fault will continue to exist. KG „ 572761 271 . the Fault Localisation window is displayed as follows: Note If you have correctly identified and entered the fault. In the teacher mode. you have created an additional fault in the process. Main control functions of CIROS® Advanced Mechatronics 6. © Festo Didactic GmbH & Co. If you have erroneously identified and entered the cause of the fault as a mechanically misaligned sensor. the sequence of the system will be executed error-free in the next simulation cycle.4.

The entries contain the following data Date Time Correctly identified and eliminated faults are highlighted in green. Logging error elimination Authorised persons have the option of viewing the log file. 272 © Festo Didactic GmbH & Co.16 Each action in the Fault Localisation window is recorded in a log file. KG „ 572761 . Main control functions of CIROS® Advanced Mechatronics 4. The log file contains a list of activities carried out in the fault localisation window.4.

provided that you have not changed this since installing CIROS® Advanced Mechatronics. Note If you want to delete the fault log. Enter the password. The preset default password is still valid. Main control functions of CIROS® Advanced Mechatronics This is how you view the log file 1. © Festo Didactic GmbH & Co. The Fault Log window is now displayed. 2. The dialog box for the password entry is now displayed. Note that the password is case sensitive.4. Open the fault log window by activating the Fault Log entry in the Extras menu under Fault Simulation. KG „ 572761 273 . Enter didactic under password. activate the context-sensitive menu via the right mouse button and select the appropriate command. Confirm your entry with OK. 3.

design and test communication between the intelligent stations of a distributed system. This training aim deals with all the topics which can be addressed by means of simulated processes of distributed systems. To carry out systematic fault finding as part of servicing and maintenance of distributed systems. Training contents and complex sections of production systems. With CIROS® Advanced Mechatronics you are imparting methodological and handling competence. 274 © Festo Didactic GmbH & Co. The main focus of training is aimed at a methodical procedure. To create. modify and test the PLC programs for the individual stations of a distributed system or complete system. KG „ 572761 . training aims Main training aims The general training aims of CIROS® Advanced Mechatronics are to achieve the following skills To design and construct PLC controlled systems in the form of distributed systems. To specify. These training contents can be taught using CIROS® Advanced Mechatronics CIROS® Advanced Mechatronics is a multimedia training aid dealing with the subject of automated systems.1 CIROS® Advanced Mechatronics provides process models for different. 5.5. The examples used relate to practical applications in industry and the problem definitions are based on industrial handling sequences and are aimed at a holistic training process.

These training contents can be taught using CIROS® Advanced Mechatronics General training aims The following general training aims can be derived from the main training aims: The user designs a production process in the form of a distributed process and creates the appropriate system. The user familiarises himself/herself with component based automation (object-oriented procedure during the design and construction of a system) in practice and uses this. The user familiarises himself/herself with preassembled MPS standard or MPS 500-FMS systems and understands their design and mode of operation. The user selects a transport system for a system and integrates this into the system. The user transmits communication information to the PLC program in the form of parameters via an interface. The user understands "intelligent units" as re-usable technological modules. KG „ 572761 275 . tests and observes communication information in the PLC programs of the "intelligent units". The user designs the communication of a distributed system. modifies and tests PLC programs for individual "intelligent units". The user practises structured and modular PLC programming. The user specifies the communication interface between the different "intelligent units" of a distributed system. The user locates and eliminates faults in the individual "intelligent units". The user incorporates. The user designs. whereby certain specific control functions are realised. The user carries out systematic fault finding in complex systems.5. © Festo Didactic GmbH & Co.

Conversely. Maintenance technicians must be able to understand electrical and electronic control technology up to a certain level to be in a position to reach conclusions regarding mechanics. Operators and fitters assume small maintenance tasks and eventual repairs. Optimisation of systems. KG „ 572761 . Modularisation of systems and distributed intelligence. Continual improvement processes. By classifying these necessary requirements. The keywords here are optimal utilisation of high investment. 276 © Festo Didactic GmbH & Co. pneumatics and hydraulics. These training contents can be taught using CIROS® Advanced Mechatronics Significance of training Industrial development over the last few years has been governed by an contents in industrial ever increasing degree of automation. more and more complex work practice processes and faster operational sequences. flexible and cost effective production. These changing requirements in turn also lead to new forms of collaboration.5. As a result of the above. Reduction in downtimes. These include: High machine efficiency. completely new requirements need to be met to some extent by all those in direct contact with a system. electrical engineers require knowledge regarding pneumatic and hydraulic actuators. these skills also include handling and methodological competence. Apart from technical knowledge. the following areas are created Technology know-how System know-how and understanding Sociocultural skills CIROS® Advanced Mechatronics enables you to develop know-how and learn skills in the areas of technology know-how and system know-how and understanding.

3 The following prior knowledge is required for training and working with Prior knowledge CIROS® Advanced Mechatronics: Basic knowledge of control technology: Structure of an automated system Basic knowledge of PLC technology: Design and mode of operation of a PLC Basic knowledge of PLC programming and handling of a PLC programming tool such as the programming system SIMATIC STEP 7 Basic knowledge of pneumatic control technology: Drives. control elements Basic knowledge of sensor technology: Limit switches.5. DC and AC current. KG „ 572761 277 . These training contents can be taught using CIROS® Advanced Mechatronics 5. PLC programming and the maintenance and servicing of networked systems or who require basic knowledge of these subjects. wiring and tubing up of electropneumatic systems. contactlessly operating proximity sensors Basic knowledge of design. These include: Vocational training ‟ Mechatronic engineers ‟ Electronics engineers. Basic knowledge of electrotechnology: Electrical variables. the correlation and calculation thereof. electrical measuring techniques Basic knowledge of how to read and interpret circuit diagrams Skills in dealing with and operating Windows programs © Festo Didactic GmbH & Co.2 The target group for CIROS® Advanced Mechatronics includes all those Target group whose vocational line of activity involves networking. for example specialising in automation technology ‟ Plant electronics engineers ‟ Industrial mechanics Specialist qualification in the metal and electrical engineering field Training at technical colleges and universities 5.

Example: Allocation of PLC programming. KG „ 572761 . for example in the syllabi for electrical and electronics engineers. 278 © Festo Didactic GmbH & Co. communication and systematic fault finding. These training contents can be taught using CIROS® Advanced Mechatronics 5.5. in Germany. The training aims to syllabi training aims are taken from the vocational training syllabus for mechatronics engineers. status 2003. The tables only lists those training aims which form part of CIROS® Advanced Mechatronics training.4 Below is a table of training aims on the subjects of system know-how. status 1999. The skilled trades of mechatronics or electronics engineers are two examples of how. skilled trades are currently updated and adapted to the concept of new training areas. The contents are correspondingly adapted and weighted.

Configuring a control system (block diagram). basic logic operations. KG „ 572761 279 . Understanding signals and measured values in control systems. Reading signal flow. protective circuits. © Festo Didactic GmbH & Co. pneumatics and hydraulics. Training area 4: Reading basic circuits of control technology: Actuation Examining energy and (pneumatic and hydraulic) of a single-acting and double- information flow in acting cylinder. signal behaviour and use of components (sensors and actuators). subsystems Understanding and evaluating the mode of operation. mechatronic systems Designing and interpreting block diagrams. These training contents can be taught using CIROS® Advanced Mechatronics Training content: Analysis of mode of operation and structure of a system Vocation Training area Training aim Mechatronics Training area 1: Reading and using technical documentation. Understanding basic circuits and the mode of operation of drives. electrical.5. Understanding and describing the control functions of simple control systems. engineer Analysing of functional Mastering the procedure for analysing and documenting correlations in functional correlations. pneumatic digital circuits. and hydraulic modules Reading and using circuit diagrams. material flow and energy flow with the help of technical documentation. Familiarisation with supply units in electrics. Training area 7: Understanding and describing the structure of Realising mechatronic mechatronic subsystems.

To examine the signal generation. KG „ 572761 . complex mechatronic mechanical. Training area 9: Describing the information structure (signal structure. signal transport) of a system. pneumatic and hydraulic components. systems Analysing signals (binary. information flow in Setting up the connection between electrical.5. These training contents can be taught using CIROS® Advanced Mechatronics Training content: Analysis of mode of operation and structure of a system Vocation Training area Training aim Training area 8: Describing the structure and signal characteristics of a Design and mechatronic system. construction of a Analysing the effect of changing operating conditions on mechatronic system the process sequence. Using computer-aided diagnostic methods such as testing and diagnostic functions of the programming system or bus system. Training area 11: Analysing mechatronic systems on the basis of technical Commissioning. analogue. fault documentation and separating the construction into finding and repairs function blocks. digital) and establishing possible error sources. Handover of Drawing up operating instructions and documentation. Training area 13: Describing a mechatronic system. mechatronic systems to customers 280 © Festo Didactic GmbH & Co.

These training contents can be taught using CIROS® Advanced Mechatronics Training contents: PLC programming and testing of the program Profession Training area Training aim Mechatronics Training area 7: Understanding the design and mode of operation of a engineer Realising mechatronic PLC. KG „ 572761 281 . Training area 8: Programming of mechatronic systems in one of the Design and programming languages: Ladder diagram. construction of statement list. Training area 9: Using computer-aided diagnostic methods such as Examining the testing diagnostic functions of the programming system. information flow in complex mechatronic systems Training area 11: Eliminating errors in the PLC program. memory functions. subsystems Designing and documenting control systems for simple applications. Programming a sequence control. fault finding and repairs © Festo Didactic GmbH & Co. Documenting control systems in function diagrams and function chart to DIN EN 60848. Commissioning.5. mechatronic systems Programming operating mode sections. sequence language. Programming simple control processes using a PLC: Logic operations. Realising the programming in one of the PLC programming languages: Ladder diagram or statement list to DIN EN 61131-3. counters. timers. function chart.

5. 282 © Festo Didactic GmbH & Co. These training contents can be taught using CIROS® Advanced Mechatronics Training contents: Communication within a system Profession Training area Training aims Mechatronics Training area 9: Describing the information structure of a system with the engineer Examining the help of circuit diagrams and technical documentation. Incorporating changes into existing documentation. Understanding and realising the networking of subsystems. Using computer-aided diagnostic methods such as testing and diagnostic functions of the programming system. information flow in Analysing signals and establishing possible error complex mechatronic sources. systems Measuring and detecting signal faults in bus systems. KG „ 572761 . Understanding hierarchies of networked systems.

information flow in Using computer-aided diagnostic methods. Commissioning. construction of Computer simulation mechatronic systems Training area 9: Analysing signals (binary. by Realising mechatronic means of signal analysis. These training contents can be taught using CIROS® Advanced Mechatronics Training content: Systematic fault finding in systems Profession Training area Training aim Mechatronics Training area 4: Fault finding on simple modules with the help of engineer Examining the energy measuring technology. digital) and Examining the establishing possible error sources. fault pneumatic and hydraulic systems.5. pneumatic and hydraulic modules Training area 7: Testing control systems for simple applications. Targeted use of diagnostic systems. eliminating error causes. Knowing typical error causes. analogue. finding and repairs Carrying out malfunction analysis. Drawing up a maintenance and repairs protocol. e. © Festo Didactic GmbH & Co.g. e. and information flow in electrical. Documentating faults. subsystems Training area 8: Identifying faults by means of signal analysis at Design and interfaces. KG „ 572761 283 . testing complex mechatronic and diagnostic functions of the programming system. systems Training area 11: Understanding procedures for fault finding in electrical.g. Mastering and using systematic fault finding.

i. Trainees can obtain technical documentation regarding the system or system components according to requirement. CIROS® Advanced Mechatronics The systems can be flexibly programmed to different levels of complexity. CIROS® Advanced Mechatronics supports self-motivated and enquiring learning: The simulated system functions in the same way as an actual system. This enables you to formulate problem definitions according to the requirements and prior knowledge of trainees whereby. the actual training topic. The realistic experience with simulated processes provides a new quality of knowledge: Theoretical knowledge becomes application and practice-oriented ability. Similarly the effect of operational errors is apparent without causing damage to the system. 284 © Festo Didactic GmbH & Co.e. This enables trainees to reach and evaluate conclusions. for example.5 CIROS® Advanced Mechatronics is a motivating. The simulated processes have their own didactic quality: They are as practice-related and real as possible. this immediately shows trainees whether they have programmed the system sequence correctly. KG „ 572761 . Trainees can practise their know-how and skills on a wide variety of systems. For example. the mode of operation of individual components can be examined. It is however also possible to concentrate on the subject and training for planning the communication in a distributed system or programming and testing the operating mode part of a system.5. The possibility of experimenting with process models establishes an affective link to actual systems. These training contents can be taught using CIROS® Advanced Mechatronics 5. thereby testing and consolidating knowledge. multimedia training aid The training concept of on the subject of automated systems.

appropriate simulation of system components or of the complete system is used to test the PLC program. A system. Efficient. available only once in reality. is available in multiple forms. All systems simulated in CIROS® Advanced Mechatronics are also available in the form of actual systems. operators and maintenance staff are often familiarised with and trained on simulated systems. Activities and skills which can only be acquired on actual systems should not be replaced but merely supplemented.5. Simulated processes can be used to illustrate and test situations which would be dangerous on an actual system. prepared or dealt with more extensively. Example 1: To ensure that PLC programs and the design of a system are completed at the same time. KG „ 572761 285 . practice-related and task oriented training is possible even without an actual system. These training contents can be taught using CIROS® Advanced Mechatronics What are the benefits of tuition using CIROS® Advanced Mechatronics? CIROS® Advanced Mechatronics is a PC-assisted training aid and therefore represents a different training method. Know-how and skills acquired on actual systems can be improved and consolidated using practice-related process models. Simulation is a modern tool used in dealing with automated systems. Example 2: Since production systems should have as few downtimes as possible. © Festo Didactic GmbH & Co. The real and virtual world of automation technology can be combined in any way and adapted to the training process required. This provides ideal additions and combinations for tuition. This increases the availability of the system for tuition. Lessons can be made stimulating and motivating.

286 © Festo Didactic GmbH & Co. Information is available on the online Help and via an online Assistant. On the basis of a library with automation stations. the user plans and designs distributed systems of varying complexity. Since the control and communication of the system can be automatically generated. CIROS® Advanced Mechatronics in the form of an introduction for the purpose of motivation and preparation on the subject of distributed automation systems: CIROS® Advanced Mechatronics can be used independently of actual systems. Typical automation stations include warehouse administration. one can acquire comprehensive basic knowledge regarding electrical and pneumatic processes and the components involved or practise and improve the programming of distributed systems. users can familiarise themselves with the automation components and stations of their system. Information regarding the components and stations is available to the user on the online Help and via an online Assistant. the user does not require any knowledge of PLC programming and networking of systems for this phase. processing machines and transport systems. With CIROS® Advanced Mechatronics users have the possibility of creating their actual MPS system in the form of a virtual system. These training contents can be taught using CIROS® Advanced Mechatronics 5.5. robots. With the help of this virtual system.6 CIROS® Advanced Mechatronics can be used in many different ways for Training scenarios for vocational and further training. In line with the user’s problem definition. KG „ 572761 . System production can be immediately simulated and the behaviour of the system observed. Here are a few examples: CIROS® Advanced CIROS® Advanced Mechatronics in the form of an introduction for Mechatronics the purpose of motivation. the user does not require any knowledge of PLC programming and networking of systems. The sequence of the system can be simulated immediately and the behaviour of the system observed. Since the control and communication of the system can be automatically generated. preparation and as a knowledge database for actual MPS systems: The user has an actual MPS system which he/she wants to understand and operate.

On the basis of two libraries with automation stations. the user can simulate the running of the system. Via the simulation. gain an understanding of distributed processes and practise and improve the programming of a distributed system. KG „ 572761 287 . A major advantage is that users can use the PLC and programming system of their choice. the user immediately receives feedback as to whether the sequence of the corresponding station has been correctly programmed. he/she can change or completely recreate the PLC programs of the individual stations. whereby they have access to the testing and diagnostic functions of the programming system. If the user has prior knowledge in PLC programming.5. These training contents can be taught using CIROS® Advanced Mechatronics In line with the user’s problem definition. In the case of less practised PLC programmers. © Festo Didactic GmbH & Co. In this way all the training contents for which only a single station is required can be taught in CIROS® Advanced Mechatronics. As soon as the desired PLC program is available. one can acquire comprehensive basic knowledge regarding electrical and pneumatic processes and the components involved. systems consisting of one station can also be created. the user plans and creates simple or complex virtual systems.CIROS® Advanced Mechatronics as a tool for practising PLC programming in applications of varying complexity: CIROS® Advanced Mechatronics can be used independently of actual systems. These permit quick and effective fault finding and elimination in the generated PLC program.

The statuses of PLC inputs/outputs are shown in a separate window. the connection is highlighted in blue. CIROS® Advanced Mechatronics supports you extensively during the identification and evaluation of the ACTUAL status of the system: LEDs on the sensors and valves indicate the electrical status of the process components. The task of the trainee is to detect and eliminate the malfunctions during the operation of a system. 288 © Festo Didactic GmbH & Co. KG „ 572761 . If compressed air is applied to a cylinder connection. These training contents can be taught using CIROS® Advanced Mechatronics CIROS® Advanced Mechatronics as a tool for practising systematic fault finding on systems of varying complexity: With CIROS® Advanced Mechatronics you can create systems of varying complexity into which malfunctions can be incorporated.5. By using a nominal/actual comparison you can isolate the location of the fault and a further systematic procedure enables you to find and eliminate the fault.

Evaluating technical documentation. Familiarisation with typical components for the realisation of automated systems: Sensors and limit switches. © Festo Didactic GmbH & Co. you can operate. Familiarisation with different production processes. The systematic procedure you use and the knowledge you acquire can be used in any way you choose and of course also on actual systems.1 The following training aims can be taught with the help of CIROS® Training aims Advanced Mechatronics: Familiarisation with and understanding of the design and mode of operation of a distributed system. the PLC programs supplied are executed by the internal controller of each of the stations. 6. A system is modelled from prepared stations.6. Modelling distributed systems from intelligent stations. familiarisation and analysing of distributed systems. The stations can of course also be controlled via other PLC programs created by the user. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics CIROS® Advanced Mechatronics supports you in a number of different ways with the creation. During simulation. Whilst the system is simulated. Networking the stations of a distributed system. programmable logic controllers. pneumatic valves. observe and analyse it. Researching information. Recognising the advantage of a simulated system for industrial operation. KG „ 572761 289 . pneumatic linear and rotary drives. The PLC programs offer a possible sequence and possible operation of the individual stations of the system. electrical DC motors. The system behaviour corresponds exactly to how this is defined in the PLC programs provided for the individual stations. Operating and observing distributed systems.

Simulation of the modelled system in 3D representation and the execution of the sample PLC in the internal controllers of the individual stations. the produced measuring instruments are to be sorted. Editor for the modelling of systems.6. After the assembly process. The stations are intelligent. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 6. CIROS® Advanced Mechatronics Assistant: Makes information available online such as the description and circuit diagrams of stations. KG „ 572761 .2 CIROS® Advanced Mechatronics supports you with the following during Support via CIROS® the creation and familiarisation with distributed systems: Advanced Mechatronics Library with prepared stations or station combinations. Answer the following questions: Which stations do you require for the system? In which sequence must be stations be arranged? How is the initial position of the system defined? Which workpieces are required for the production process? How does the station react if a slide is filled with workpieces on the sorting station.3 Example: Configuration of a distributed system from MPS® Standard stations and simulating production Exercise Configure a system for the production of measuring instruments. Manual Operation window: Status display of all process sequences and statuses. 290 © Festo Didactic GmbH & Co. Windows for PLC inputs/outputs: Status display of the PLC inputs/outputs of a station. Manual Operation window: Manual triggering of process sequences. The workpiece housings for measuring instruments are to be supplied via the handling station. 6. autonomous system sections which perform specific machine functions.

Then click onto the Save button. © Festo Didactic GmbH & Co. Activate the MPS® System command under New in the File menu. Enter the file name. 2. 3. The Create MPS® System window is now displayed.mod). Select CIROS® Workcells (*. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics Implementation 1. KG „ 572761 291 . Start CIROS® Advanced Mechatronics. Select a subdirectory for the new station as storage location.under file type.6.

KG „ 572761 . ‟ A table with possible workpieces is made available. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 4. ‟ The view selected is Top View. ‟ The Model Libraries window is opened.6. When a new system is created. a number of settings are carried out automatically in CIROS® Advanced Mechatronics: ‟ The program changes into Edit Mode. The model of an empty system is now displayed. 292 © Festo Didactic GmbH & Co.

A brief description and preview of the individual models is displayed if you highlight the library entry for the model and then click onto the Details button. © Festo Didactic GmbH & Co. KG „ 572761 293 .6. Create the required system using the station models from the MPS® Stations Library. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 5.

KG „ 572761 . Start Help by activating the Examples and Models of CIROS® Advanced Mechatronics command in the Help menu. 294 © Festo Didactic GmbH & Co. You will find detailed information regarding the stations in the library on the online Help in the chapter CIROS® Advanced Mechatronics. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 6. For example a function description and technical documentation for the station are offered.6.

Now check which station you need for the required system and how the system is to be configured. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 7.6. KG „ 572761 295 . © Festo Didactic GmbH & Co. The stations are placed directly next to one another and are coupled via optical sensors. Result Your investigation shows that you will need the Pick & Place and Fluidic Muscle press stations for the assembly process. In addition you will also need the handling station – adjusted for successor station and the sorting station.

296 © Festo Didactic GmbH & Co. Now create the system. This station is shown in green since it is still highlighted. The system now consists of the handling station– adjusted for successor station model. Since an additional station will be added to the handling station. To entries are available to you for this station in the library. Highlight the entry Handling – Adjusted for Successor via a mouse click.6. you require the handling station – adjusted for successor station. KG „ 572761 . First insert the handling station. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 8. Then click the Add button.

This indicates that the station can be connected to an additional station at this point.6. A coupling point is shown on both sides of the station. Simply click outside of the station if you want to cancel the highlighting of the station. KG „ 572761 297 . This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 9. © Festo Didactic GmbH & Co.

Now enter the Pick & Place station as an additional station. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 10.6. KG „ 572761 . 298 © Festo Didactic GmbH & Co.

KG „ 572761 299 . All stations are inserted at the same position of the work space. The two models are positioned next to one another but are not yet connected. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 11. Move the newly added Pick & Place station by clicking onto the highlighted station and moving the mouse pointer to the required position whilst holding down the left mouse button. To ensure that working and transfer positions coincide during the production run of the system.6. © Festo Didactic GmbH & Co. 12. both station models must be correspondingly aligned and connected.

To do so. The Pick & Place station is now connected to the handling station – adjusted for successor station. KG „ 572761 . 300 © Festo Didactic GmbH & Co. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 13. click onto the bottom grey shaded coupling point of the Pick & Place station.6. Hold down the left mouse button and drag the coupling point onto the coupling point of the handling station - adjusted for successor station. Now align the Pick & Place station model with the handling station – adJusted for successor station.

Now enter the Fluidic Muscle press station as the next station.6. © Festo Didactic GmbH & Co. This station is also shown at the predefined point in the activity window. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 14. KG „ 572761 301 .

still highlighted station and move this up next to the Pick & Place station. KG „ 572761 . This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 15. Click onto the newly added. 302 © Festo Didactic GmbH & Co.6.

To do so click onto the lower. Hold down the left mouse button and drag the coupling point to the free coupling point of the Pick & Place station. grey shaded coupling point of the Fluidic Muscle press station. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 16. Connect the Fluidic Muscle press station model to the upper. free coupling point of the Pick & Place station model.6. © Festo Didactic GmbH & Co. KG „ 572761 303 .

Change into the view mode to obtain a realistic 3D representation of the system. The system is now configured. Deactivate the Edit Mode command in the Modeling menu by clicking onto the Edit Mode command. 304 © Festo Didactic GmbH & Co. Connect the sorting station to the Fluidic Muscle press station. 18. Add the sorting station as the last station. The check mark next to the Edit Mode entry is removed. KG „ 572761 . This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 17.6.

This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 19.6. © Festo Didactic GmbH & Co. KG „ 572761 305 . A 3D representation of your system is displayed. The representation also shows a top view.

all the workpieces on the system are also removed. To obtain a perspective view of the 3D model. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 20. the system should be in the initial position. select the Standard Views/Default Settings command in the View menu. Move. rotate and zoom into an appropriate view of your system by using the commands under View. 21.6. Prior to simulating production of the system. This is achieved by executing the Reset Workcell command in the Simulation menu. KG „ 572761 . By executing this command. 306 © Festo Didactic GmbH & Co.

This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 22. Each station has an internal PLC. Once simulation is started. the illuminated reset button requests the reset function for all stations. The stations can now be operated using the keys and switches of the corresponding control console. Now activate the Start command in the Simulation menu. 24. KG „ 572761 307 . The sequence of operation is defined in the PLC program. © Festo Didactic GmbH & Co. 23. Simulation of the system is now active. The system is moved into the initial position via the reset function.6. You can identify the simulation mode via the Running entry. The supplied sample PLC program is executed with the start of virtual system simulation.

open the CIROS® Advanced Mechatronics Assistant. 308 © Festo Didactic GmbH & Co.6. Click onto the CIROS® Advanced Mechatronics entry. KG „ 572761 . This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 25. Activate the Examples and Models of CIROS® Advanced Mechatronics command in the Help menu. In the chapter MPS® Standard you will find the required information regarding the individual stations in the technical documentation. To obtain information in the technical documentation regarding the initial position of the system.

Initial position for the Pick & Place station: Feed separator advanced and conveyor motor off. KG „ 572761 309 . Mini slide up and mini slide retracted and vacuum off.6. © Festo Didactic GmbH & Co. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics Result Initial position for the handling station: Linear axis in "predecessor station" position (1B2=1) and lifting cylinder retracted (gripper up) and gripper open. Initial position for the sorting station: Locking device advanced and sorting gate 1 retracted and sorting gate 2 retracted and conveyor motor off. Initial position for the Fluidic Muscle Press station: Linear drive retracted and rotary drive in pick-up position ("predecessor station position") and pressb up.

6. 28. 27. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 26. then the reset mode of the Fluidic Muscle press station. Execute the reset function for each station by clicking the reset button. KG „ 572761 . The illuminated start button of a station indicates that the respective station is now in the initial position. this means: Execute the reset mode of the sorting station. You will find the information for this in the technical documentation for the individual station in CIROS® Advanced Mechatronics Assistant. Check whether the start conditions for the individual stations are fulfilled. 310 © Festo Didactic GmbH & Co. followed by that of the Pick & Place station and finally the reset mode of the handling station. We recommend that you carry out the reset of the individual stations against the material flow. In the case of this system.

KG „ 572761 311 . This is how you create and operate a distributed system in CIROS® Advanced Mechatronics Result Start conditions of the individual stations: Handling station: Workpiece in the workpiece holde Pick & Place station: No workpiece at conveyor start and slide with workpiece inserts filled Fluidic Muscle press: No workpiece in gripper Sorting station: No workpiece at conveyor start 29. ‟ At least one workpiece insert on the slide of the Pick & Place station.6. Make sure that the workpieces necessary for the production process of the system are available: ‟ One workpiece housing at the transfer position of the handling station. © Festo Didactic GmbH & Co.

This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 30. Then click onto the symbolic workpiece of the handling station. 312 © Festo Didactic GmbH & Co. A red measuring instrument housing is made available on the workpiece holder of the handling station. For example select the red measuring instrument housing. click onto the desired workpiece on the workpiece table. To supply a workpiece to the handling station.6. KG „ 572761 .

6. © Festo Didactic GmbH & Co. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 31. Now fill the slide of the Pick & Place station with measuring instruments by clicking onto the symbolic measuring instrument of the Pick & Place station. KG „ 572761 313 .

If you want to restart the station. We recommend that you start the stations in the order in which they are arranged in the material flow. With the key actuator you can select either continuous cycle (switch position vertical) or individual cycle (switch position horizontal) for a station sequence. 34. KG „ 572761 . you need to execute the reset function first. 33.6. Start the sequence of each station by clicking onto the start button. 314 © Festo Didactic GmbH & Co. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 32. The automatic mode of the station is started. The sequence of a station can be interrupted at any time by pressing the stop button.

the station does not accept any additional workpieces. If a slide of the sorting station is filled with workpieces. KG „ 572761 315 .6. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 35. © Festo Didactic GmbH & Co. Warning light Q1 is illuminated.

KG „ 572761 . This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 36. 316 © Festo Didactic GmbH & Co. Remove the workpieces by executing the appropriate command in the manual operation window. Double click onto the + symbol in front of sorting station on the left side of the window to display all the activities of the station. Double click the Empty Slides entry. Click onto the Manual Operation command in the Modeling menu.6.

KG „ 572761 317 . © Festo Didactic GmbH & Co. The production process of the system is then continued. This is how you create and operate a distributed system in CIROS® Advanced Mechatronics 37.6. Acknowledge the removal of the workpieces by pressing the start button.

In the standard version. The networking is dealt with in the form of an example using the distributing.7. The user analyses how simple communication functions and how it is realised. Note In the case of the distributing station only the StationLink receiver is mounted. By switching on and off the StationLink emitter. The StationLink emitter is mounted on the material input side of the station and the StationLink receiver on the material output side. 318 © Festo Didactic GmbH & Co. testing and sorting stations. This type of coupling is known as StationLink. KG „ 572761 . MPS® Standard stations are coupled with optical sensors. In the case of the sorting station. The PLC programs are created such that they can be used for stand alone operation of the stations. these PLC programs also support working with the stations in a network whereby minimal information about process inputs/outputs is exchanged between the stations. Through- beam sensor emitters and receivers are used as StationLink sensors. only the StationLink emitter is mounted. the predecessor station signals whether it is ready to accept a workpiece or occupied. This is how you analyse information flow in a distributed system The exercise is intended as an introduction to the subject of networking stations. At the same time.

Evaluating technical documentation.7.2 Proceed step by step to analyse the networking and information flow in Methods a system. Recognising the advantage of a simulated system for industrial operation. Each step deals with an important aspect of communication. Incorporating simple communication into the PLC program of a station. © Festo Didactic GmbH & Co. Understanding structured. Questions regarding the individual aspects offer suggestions and guidance as to what you should examine and consider. This is how you analyse information flow in a distributed system 7. 7. Realising simple communication between stations via process inputs/outputs. KG „ 572761 319 . programmed PLC programs. The main aspects of communication are listed below. Researching information.1 The following training aims can be taught with the use of CIROS® Training aims Advanced Mechatronics: Understanding simple communication between the stations of a distributed system.

7. This is how you analyse information flow in a distributed system Main aspects Questions Function of communication What is the function of communication? ‟ To ensure the safe transfer of workpieces ‟ To transmit information regarding the workpieces ‟ To pass on job orders to the stations Information that is exchanged How does communication function? ‟ What is the meaning of the signal which the information transmits? ‟ Via which absolute address is the signal evaluated? ‟ What data type is the signal? Realisation of communication How is communication realised? ‟ Via the coupling of PLC inputs/outputs ‟ Via the use of a fieldbus Components for communication What components are used to establish communication: ‟ Direct connection of PLC inputs/outputs ‟ Optical sensors for signal transmission ‟ Communication modules in field devices Structure of communication How are the components assembled? What needs to be considered when connecting stations? Connection of components What does the connection of components look like? Communication in PLC How is communication incorporated into PLC programs? programs Is communication information transmitted to the relevant program sections via global variables or via parameters? Main aspects of communication within a system 320 © Festo Didactic GmbH & Co. KG „ 572761 .

4 Example: Analysing information flow in a distributed MPS® Standard system Exercise Analyse the communication in an MPS® Standard system. 7.3 CIROS® Advanced Mechatronics supports you as follows during the Support via CIROS® analysis of communication in distributed systems: Advanced Mechatronics Simulation of the modelled system in 3D representation and execution of sample PLC programs in the internal controllers of individual stations. Select the combination of the distributing. Manual operation window: Status display of communications links. CIROS® Advanced Mechatronics Assistant: Online information such as descriptions. circuit diagrams and PLC programs of stations. testing and sorting stations as the system. Manual operation window: Status display of all process activities and process statuses.7. KG „ 572761 321 . what is to be considered when coupling the stations? What does the connection of components look like? How is communication incorporated into the PLC programs? © Festo Didactic GmbH & Co. This is how you analyse information flow in a distributed system 7. Windows for PLC inputs/outputs: Status display of the inputs/outputs of a station. Consider the following questions when analysing the communication: What is the function of communication? What information is exchanged? How is communication realised? Via what components is communication established? How are the components assembled.

This is how you analyse information flow in a distributed system Implementation 1.7. 2. KG „ 572761 . testing and sorting stations. 3. Create an MPS® Standard system consisting of the distributing. Change to View mode by clicking the Edit Mode command in the Modeling menu. The check mark next to the Edit Mode entry is removed. select the station with the library entry Distributing – Adjusted for Testing in the model library. Deactivate the Edit Mode as soon as the station is created. Start CIROS® Advanced Mechatronics. As the distributing station is coupled with the testing station. 322 © Festo Didactic GmbH & Co.

create the desired representation of the system. © Festo Didactic GmbH & Co. KG „ 572761 323 . Close the model library and select a perspective view of the system by activating the Standard Views/Default Setting command in the View menu. Using the command in the View menu. This is how you analyse information flow in a distributed system 4.7.

To do so. 324 © Festo Didactic GmbH & Co. This is how you analyse information flow in a distributed system 5. KG „ 572761 . Click onto the CIROS® Advanced Mechatronics entry. activate the Examples and Models of CIROS® Advanced Mechatronics command in the Help menu. Refer to the technical documentation on the online Help to find out what functions communication realises in MPS® Standard systems.7. In the chapter Getting Started you will find a section about communication between stations.

KG „ 572761 325 .7. © Festo Didactic GmbH & Co. This is how you analyse information flow in a distributed system Result The function of communication is to enable the reliable transfer of a workpiece from the distributing station to the testing station.

Use the technical documentation for the two stations for information as to how communication functions: ‟ Which information is transmitted? ‟ Which data type carries the signal which transmits information? Result Distributing station Testing station Material flow “Station occupied” bit “Station occupied” = 1 means: Testing station has no requirement.7. Distributing station is permitted to output. Station occupied = 0 means: Testing station has requirement and requests a workpiece. KG „ 572761 . Distributing station must not output. 326 © Festo Didactic GmbH & Co. This is how you analyse information flow in a distributed system 6.

In the chapter MPS® Standard you will find the appropriate stations and relevant technical documentation. Click onto the CIROS® Advanced Mechatronics entry. © Festo Didactic GmbH & Co. This is how you analyse information flow in a distributed system 7. KG „ 572761 327 . Refer to the technical documentation for the two stations to find out what system resources the PLC uses to realise communication. To do so activate the Examples and Models of CIROS® Advanced Mechatronics command in the Help menu.7.

KG „ 572761 . Information is exchanged Information is exchanged via via Input of the PLC Input of the PLC Output of the PLC Output of the PLC Distributing station Testing station “Station occupied” bit I 0.7 328 © Festo Didactic GmbH & Co.7 Q 0.7. This is how you analyse information flow in a distributed system Result Distributing station Testing station “Station occupied” bit 0-Signal 1-Signal 1-Signal 0-Signal The signal is inverted at the receiving end.

Find out what is to be considered when coupling the stations. emitter © Festo Didactic GmbH & Co. Result Sheet Column Designation Circuit diagram of distributing station 4 9 Sensor IP_FI. 10. receiver Components of the testing station Optical sensor: Through-beam sensor. KG „ 572761 329 . receiver Circuit diagram of testing station 5 9 Sensor IP_N_FO. through-beam sensor. through-beam sensor. This can be achieved by connecting the stations via the coupling points. the optical sensors of the neighbouring stations must be positioned flush and directly opposite one another. emitter 9. Refer to the technical documentation to find out where in the diagram the components for the realisation of communication are taken into account. Refer to the technical documentation for the two stations to find out which components are used to transmit the information "Station occupied". This is how you analyse information flow in a distributed system 8.7. Result To ensure that the communication signal is transmitted error-free via the optical StationLink sensors. Result Components of the distributing station Optical sensor: Through-beam sensor.

330 © Festo Didactic GmbH & Co. Reset the individual stations agains the material flow. The illuminated reset button requests the reset function on all stations. Start simulation by activating Start in the Simulation menu.7. This is how you analyse information flow in a distributed system 11. 12. Now observe the production process of the system. 13. KG „ 572761 .

for example. click onto the required workpiece on the workpiece table.7. © Festo Didactic GmbH & Co. Then click onto the symbolic workpiece on the distributing station. To do so. Fill the magazine of the distributing station with. Make sure that the required workpieces are available for the production process of the system. This is how you analyse information flow in a distributed system 14. Each mouse click on the symbolic workpiece causes the magazine to be filled with a workpiece. red basic cylinder bodies. KG „ 572761 331 .

7. KG „ 572761 . We recommend that you start the stations in the order in which they are arranged in the material flow. Once all the workpieces have been tested and sorted. Start the sequence of each station by clicking onto the start button. stop the simulation by clicking onto the Running field. 16. 332 © Festo Didactic GmbH & Co. This is how you analyse information flow in a distributed system 15.

Hide the section of the window with the display of I/O connections as you do not need this information. To do so.7. 18. This is how you analyse information flow in a distributed system 17. open the Manual Operation window in the Modeling menu. KG „ 572761 333 . then set the stops at the appropriate signals. Next observe the status of the communication variables during the production process of the system. If you merely want to observe the changes in communication signals. Activate the context-sensitive menu via the right mouse button and deactivate the Show I/O Connections command. 19. Simulation stops as soon as the relevant signal changes its value and you can observe the sequence at your leisure. © Festo Didactic GmbH & Co.

This is how you analyse information flow in a distributed system 20. All the process sequences of the distributing station are now displayed. KG „ 572761 . The process statuses of the testing station can be displayed in the righthand section of the window.7. Double click the + symbol in front of the distributing station in the lefthand section of the window. 334 © Festo Didactic GmbH & Co.

Highlight the variable IP_N_FO station occupied of the testing station under Process Status and set a stop. KG „ 572761 335 . Open the context- sensitive menu of the righthand mouse button and select the Stop at Value Change command. The variable IP_N_FO is marked with a STOP symbol.7. This is how you analyse information flow in a distributed system 21. © Festo Didactic GmbH & Co.

7. Open the PLC inputs window to also observe the communication signal of the distributing station. 336 © Festo Didactic GmbH & Co. KG „ 572761 . This is how you analyse information flow in a distributed system 22. Activate the Show Inputs command under Inputs/Outputs in the View menu.

KG „ 572761 337 . This is how you analyse information flow in a distributed system 23. © Festo Didactic GmbH & Co. Click onto the Controller Selection command in the Programming menu.7. Select the controller whose PLC inputs/outputs you want to observe. In the Current column. Start simulation of the system by clicking onto the Stopped button in the status bar. 24. select the controller for the distributing station as controller.

26. The indicator light Q1 on the control console of the distributing station indicates the workpieces are missing. This is how you analyse information flow in a distributed system 25. 338 © Festo Didactic GmbH & Co. 27. KG „ 572761 . Acknowledge the activity and click onto the illuminated start button. Fill the magazine of the distributing station with correct workpieces again.7.

KG „ 572761 339 . The distributing station ejects a new workpiece from the magazine and passes it on to the testing station. This is how you analyse information flow in a distributed system 28.7. 29. because the station has no requirement. A workpiece is already present in the holder. © Festo Didactic GmbH & Co. The testing station signals "station occupied=1". Restart simulation to continue the execution of the production process by clicking onto the Stopped button in the status bar. Simulation then stops because the Variable IP_N_FO of the testing station changes its value.

The distributing station must therefore not pass on a further workpiece to the testing station.7. Its value is changed to 0. KG „ 572761 . This is how you analyse information flow in a distributed system 30. In the next simulation cycle. the signal STATION_IP_FI successor station free of the distributing station is updated in the Inputs window. 340 © Festo Didactic GmbH & Co.

This is how you analyse information flow in a distributed system 31. It now sends the signal "Station occupied=0". KG „ 572761 341 . it can accept a new workpiece. © Festo Didactic GmbH & Co. The signal change causes simulation to stop.7. Restart simulation. The testing station changes the value of the variable IP_N_FO. As soon as the station has completed the process of testing and passed on the workpiece to the sorting station. 32. The testing station now tests the current workpiece.

It is therefore permissible for the distributing station to start output. In the GRAFCETs for the stations you can reproduce in detail how and at which points in the PLC program communication is taken into consideration. In the next simulation cycle. the signal "station occupied" is read inverted as "successor station free" by the distributing station. KG „ 572761 .7. This is how you analyse information flow in a distributed system 33. With the simulation of the system you have now analysed how communication between the distributing and testing stations functions. 342 © Festo Didactic GmbH & Co. 34. You will find the GRAFCETs in the technical documentation for the stations.

KG „ 572761 343 .7. You can analyse the communication between the testing and sorting stations in the same way by using simulation and the technical documentation. © Festo Didactic GmbH & Co. This is how you analyse information flow in a distributed system 35.

KG „ 572761 . This is how you analyse information flow in a distributed system 344 © Festo Didactic GmbH & Co.7.