Bosch Rexroth AG | mMS 4.0 - Station 1 Project 01: mMS4.

0 – Magazine station 1

Project 01: mMS4.0 – Magazine station

Project definition
A pneumatic cylinder pushes a cube half out of the separator magazine on the
conveyor belt. The belt transports the workpiece past the testing unit. A sensor at the
end of the belt detects the cube half and the belt drive stops the motion. To start the
sequence, the Start push button is to be operated and the sequence is to be stopped
when the light barrier is interrupted.

mMS4.0, Magazine station

Project task
▶ Create a new IndraWorks project
▶ Create the required hardware configuration
▶ Create a list of variables
▶ Program the automatic mode
▶ Add the testing procedure
2 Project 01: mMS4.0 – Magazine station Bosch Rexroth AG | mMS 4.0 - Station 1

Hardware configuration for the magazine station

The following figure shows the configuration of the hardware to be created in
IndraWorks project explorer. All properties which are not listed can be found at the
station. If you cannot find the information, choose them freely.

%IB0
%IB1
%QB0
%QB1

%IB100

%IB108, %QB108
%IB110, %QB110
%IB112

%IB150, %QB150

IndraWorks project explorer

Configuration of the PLC

▶ Device name Station1_Magazine

▶ PLC configuration:
- Device type: to be found at the station.
- Firmware version: to be found at the station
- Firmware release: to be found at the station
- IP address: to be found at the station
- PLC gateway: localhost
- PLC communication: TCP
▶ PLC interfaces:
- Profibus DP (X7P): Profibus DP Master
- Realtime Ethernet (X7E1/X7E2): Not used
- Ethernet (X7E5): EtherNet/IP adapter
- Functional modules: Not used

Configuration of the inline I/Os

Bosch Rexroth AG | mMS 4.0 - Station 1 Project 01: mMS4.0 – Magazine station 3

▶ Inline module: see figure above

▶ Address ranges: see figure above

Configuration of the VAM machine control desk

▶ Profibus address: 3
▶ Address range: see figure above
▶ Key pad A and key pad B should have the same byte addresses for the input key
and display LED. E. g.
- Key 1: %IX108.0,
- LED at key 1: QX108.0

Configuration of the bus coupler

▶ Profibus address: 4
▶ Inline module: see figure above
▶ Address ranges: see figure above
4 Project 01: mMS4.0 – Magazine station Bosch Rexroth AG | mMS 4.0 - Station 1

Assignment tables for station 1, magazine

PLC inline I/Os

Denomination Identifier BMK Function

address

Emergency stop relay i_EmergencyStopRelaisOk IX0.0 Emergency stop relay

active active = TRUE

Reserve 2 IX0.1

Reserve 3 IX0.2

Reserve 4 IX0.3

From next station, station i_FromNextStationAvailable IX1.0 Available = TRUE

available

From next station, station i_FromNextPreviousStation- IX1.1 Needs part = TRUE

needs part NeedPart

From previous station, i_FromPreviousStation- IX1.2 Available = TRUE

station available Available

From previous station, i_FromPreviousStationHasPart IX1.3 Has part = TRUE

station has part

Reserve 1 QX0.0

Reserve 2 QX0.1

Reserve 3 QX0.2

Reset emergency stop q_ResetEmergencyStopRelays QX0.3 Reset emergency stop

relay relay = TRUE

To next station, q_ToNextStationAvailable QX1.0 Available = TRUE

station available

To next station, q_ToPreviousStationHasPart QX1.1 Has part = TRUE

station has part

To next station, q_ToPreviousStation-Available QX1.2 Available = TRUE

station available

To next station, q_ToNextPreviousStation- QX1.3 Needs part = TRUE

station needs part NeedPart
Bosch Rexroth AG | mMS 4.0 - Station 1 Project 01: mMS4.0 – Magazine station 5

Machine control desk I/Os (VAM) – push buttons, key switch, rotary override
switches

Denomination Identifier BMK Function

address

Push button “On” IX100.0

Push button “Off” IX100.1

Key switch, pos. 1 OP_i_OM1_Hand IX101.4

Key switch, pos. 2 OP_i_OM2_Init IX101.5

Key switch, pos. 3 OP_i_OM3_Automatic IX101.6

Key switch, pos. 4 OP_i_OM4_SingleStep IX101.7

Rotary override switch 1 IB112 Gray code, axis

Rotary override switch 2 IB113 Gray code, spindle

6 Project 01: mMS4.0 – Magazine station Bosch Rexroth AG | mMS 4.0 - Station 1

Machine control desk I/Os (VAM) – key pad A

Denomination Identifier BMK Function

address

Key pad A, key 1 IX108.0

Marking: Capacitive QX108.0
Indicator

Key pad A, key 2 IX108.1

Marking: Separator QX108.1
Magazin 2

Key pad A, key 3 IX108.2

Marking: Separator QX108.2
Magazin 1

Key pad A, key 4 IX108.3

Marking: Contour Indicator QX108.3

Key pad A, key 5 IX108.4

Marking: Removing Unit QX108.4

Key pad A, key 6 IX108.5

Marking: Testing Unit QX108.5

Key pad A, key 7 IX108.6

Marking: Inductive Indicator QX108.6

Key pad A, key 8 IX108.7

Marking: QX108.8

Key pad A, key 9 IX109.0

Marking: QX109.0

Key pad A, key 10 IX109.1

Marking: Light Indicator QX109.1

Key pad A, key 11 IX109.2

Marking: QX109.2

Key pad A, key 12 IX109.3

Marking: QX109.3

Key pad A, key 13 IX109.4

Marking: JOG – QX109.4

Key pad A, key 14 IX109.5

Marking: JOG RAPID QX109.5

Key pad A, key 15 IX109.6

Marking: JOG + QX109.6
Bosch Rexroth AG | mMS 4.0 - Station 1 Project 01: mMS4.0 – Magazine station 7

Machine control desk I/Os (VAM) – key pad B

Denomination Identifier BMK Function

address

Key pad B, key 16 IX110.0

Marking: HAND QX111.0

Key pad B, key 17 IX110.1

Marking: MDI QX111.1

Key pad B, key 18 IX110.2

Marking: AUTO QX111.2

Key pad B, key 19 OP_i_SingleStep IX110.3

Marking: SINGLE STEP QX110.3

Key pad B, key 20 IX110.4

Marking: ON / OFF QX111.4

Key pad B, key 21 IX110.5

Marking: HOME QX111.5

Key pad B, key 22 IX110.6

QX111.6

Key pad B, key 23 IX110.7

QX111.8

Key pad B, key 24 OP_i_Reset IX111.0

Marking: RESET OP_q_Reset QX111.0

Key pad B, key 25 IX111.1

QX111.1

Key pad B, key 26 IX111.2

QX111.2

Key pad B, key 27 IX111.3

Marking: STOP QX111.3

Key pad B, key 28 IX111.4

Marking: Conveyor Belt QX111.4

Key pad B, key 29 IX111.5

Marking: Conveyor Belt QX111.5

Key pad B, key 30 OP_i_Start IX111.6

Marking: START OP_q_Start QX111.6
8 Project 01: mMS4.0 – Magazine station Bosch Rexroth AG | mMS 4.0 - Station 1

Separator magazine 1

Denomination Identifier BMK Denomination

address

Separator magazine 1, SM1_i_SensorCylRetracted IX150.4 Separator magazine 1,

sensor, cylinder retracted cylinder extended = TRUE

Separator magazine 1, SM1_i_SensorCylExtented IX150.5 Separator magazine 1,

sensor, cylinder extended cylinder retracted = TRUE

Separator magazine 1, SM1_i_SensorFillLevelOk IX150.6 Separator magazine 1,

sensor, filling level filling level OK = TRUE

Separator magazine 1, SM1_q_ValveCylExtend QX151.0 Separator magazine 1,

valve, cylinder extend cylinder extend = TRUE

Separator magazine 2

Denomination Identifier BMK Denomination

address

Separator magazine 2, SM2_i_SensorCylRetracted IX151.0 Separator magazine 2,

sensor, cylinder retracted cylinder extended = TRUE

Separator magazine 2, SM2_i_SensorCylExtented IX151.1 Separator magazine 2,

sensor, cylinder extended cylinder retracted = TRUE

Separator magazine 2, SM2_i_SensorFillLevelOk IX150.7 Separator magazine 2,

sensor, filling level filling level OK = TRUE

Separator magazine 2, SM2_q_ValveCylExtend QX151.1 Separator magazine 2,

valve, cylinder extend cylinder extend = TRUE

Conveyor belt

Denomination Identifier BMK Denomination

address

Conveyor belt, sensor, light CB_i_LightBarrierEnd IX150.2 Light barrier interrupted =

barrier TRUE

Conveyor belt, relay, CB_q_ProcessingDirection QX152.0 Conveyor belt motor,

motion in processing direction of rotation in
direction processing direction =
TRUE

Conveyor belt, relay, CB_q_RemovingDirection QX152.1 Conveyor belt motor,

motion in removing direction of rotation in
direction removing direction =
TRUE
Bosch Rexroth AG | mMS 4.0 - Station 1 Project 01: mMS4.0 – Magazine station 9

Testing unit

Denomination Identifier BMK Denomination

address

Testing unit, sensor, TU1_i_WorkpiecePresent IX151.2 Workpiece detected =

workpiece present TRUE

Testing unit, sensor, TU2_i_WorkpieceConturOpen IX151.3 Workpiece contour open

workpiece contour on top = TRUE
detection

Testing unit, valve, contour TU2_q_ValveCylExtend QX151.2 Cylinder extend = TRUE

cylinder

Testing unit, sensor, TU3_i_WorkpieceMetall IX152.0 Workpiece metal = TRUE

workpiece property metal

Testing unit, sensor, TU4_i_WorkpieceBright IX152.1 Workpiece bright (white,

workpiece property aluminum) = TRUE
brightness

Removing unit

Denomination Identifier BMK Denomination

address

Removing unit, sensor, RU_i_SensorCylExtended IX152.3 Sensor, cylinder extended

cylinder extended = TRUE

Removing unit, valve, RU_i_ValveCylExtend QX151.3 Cylinder extend = TRUE

cylinder extend
10 Project 01: mMS4.0 – Magazine station Bosch Rexroth AG | mMS 4.0 - Station 1

Project execution
Exercise 1

In the following figure, the sequence of station 1 is described. This automatic

sequence is to be implemented in a POE with the following properties:
- Identifier: main_sequence
- Type: program
- Implementation language: Sequential Function Chart (SFC)

Before the program code can be entered, the global list of variables is to be created.
All required details can be found in the assignment lists.

1 “Initial step”

“Start key”

2 “Magazine 1, cylinder extend”

“Magazine 1, Sensor,
cylinder extended”
“Magazine 1, cylinder retract”
3

“Magazine 1, Sensor,
cylinder retracted”

4 “Conveyor belt, processing direction”

“Light barrier interrupted

from cube half”

5 “Conveyor belt, stop”

“Cube half is taken away

from the light barrier”

GRAFCET automatic sequence

Create the program that performs the functions of the sequence described in the
GRAFCET diagram. In the 1st exercise, exclusively qualifier N (no saving) is to be
used in the actions of the steps.
Bosch Rexroth AG | mMS 4.0 - Station 1 Project 01: mMS4.0 – Magazine station 11

Exercise 2

Extension of the project by the following functions:

- Reset of the emergency stop relay using the Rest key.
- Rest key flashes when the emergency stop relay is not active.
- Start key flashes when the automatic sequence can be started.
- Start key is illuminated while the automatic sequence is running.

Exercise 3

Extension of the project by the following functions:

- As soon as the capacitive sensor at the testing unit is activated, the belt
continues running for 1-1.2 s (to be set) and is then stopped.
- The test cylinder extends for 500 ms or until the end position sensor is
activated.
- The test cylinder retracts for 500 ms.
- The belt starts running again.

4 “Conveyor belt, processing direction”

“Testing process”

“Light barrier interrupted

from cube half”

5 “Conveyor belt, stop”

“Cube half is taken away

from the light barrier”

GRAFCET automatic sequence, extension

12 Project 01: mMS4.0 – Magazine station Bosch Rexroth AG | mMS 4.0 - Station 1

Exercise 4

Up to now, only magazine 1 was used. For completion, magazine 2 is to be included

in the automatic sequence now as well.
Extension of the project by the following functions:
- Magazine 2 is to be added to magazine 1 in the alternative branch.
- The two magazines are to work alternately in the automatic sequence.

“Select magazine 1” “Select magazine 2”

“Magazine 1, “Magazine 2,
2a 2b
cylinder extend” cylinder extend”

“Magazine 1, Sensor, “Magazine 2, Sensor,

cylinder extended” cylinder extended”
“Magazine 1, “Magazine 2,
3a 3b
cylinder retract” cylinder retract”

“Magazine 1, Sensor, “Magazine 2, Sensor,

cylinder retracted” cylinder retracted”

4 “…”

GRAFCET automatic sequence, extension

Exercise 5

For the commissioning of machines, IndraWorks provides a visualization interface. It

can be furnished with operating and display elements.
Extension of the project by the following functions:
- A control from the visualization for the Start and Reset keys is to be added.
- The LED display of the two push buttons is to be included in the visualization
as well.

All required information can be

found in the Help (F1) under
“Visualization editor”.

Example of the visualization

Bosch Rexroth AG | mMS 4.0 - Station 1 Project 01: mMS4.0 – Magazine station 13

Exercise 6

During the sequence, a workpiece detection can be performed.

Extension of the project by the following functions:

- The properties of the cube half (contour on top open/closed, metal/non-metal,
bright/dark) are to be saved during the process.
- The properties are to be analyzed at the end of the process and are to be
provided in the form of a numerical value (integer). See the following table for
clarification

Dec Bin Description of the properties

0 000 Dark, non-metal, contour on top closed

1 001 Dark, non-metal, contour on top open

2 010 Dark, metal, contour on top closed

3 011 Dark, metal, contour on top open

4 100 Bright, non-metal, contour on top closed

5 101 Bright, non-metal, contour on top open

6 110 Bright, metal, contour on top closed

7 111 Bright, metal, contour on top open

Assignment of the cube properties (Dec = decimal, bin = binary)

Exercise 7

Information on workpiece properties is to be shown for the user. To achieve this, the
visualization in IndraWorks can be used. In addition, the output on the display of the
PLC can be used.

Extension of the project by the following functions:

- Display of the workpiece properties in plain text in the visualization
- Display of the workpiece properties in plain text on the PLC display. To do this,
the RIH_CMLx library has to be embedded.
Embed via Library Manager – Add library – IndraLogic – Base
14 Project 01: mMS4.0 – Magazine station Bosch Rexroth AG | mMS 4.0 - Station 1

Exercise 8

Extension of the project by the following functions:

- Display of the active step in the visualization
- Reset of the step chain if the emergency stop relay is not active and the reset
key is operated.
- Addition of the single step function
 Operating mode has to be selected
 To perform the single step, the SINGLE STEP key has to be operated
 Not for all steps, a single step is reasonable
- Determine and add the start conditions
 Filling level of the magazines
 No part in the light barrier at the end of the conveyor belt
- Addition of the filling level information to the visualization