PRACTICUM REPORT

DISTRIBUTED CONTROL SYSTEM (DCS) 2

Name SILPIA ARDIYA GARINI

NIM 217441021
Semester 5
Class 3 AED
No. Coin 392

TEKNIK OTOMASI MANUFAKTUR DAN MEKATRONIKA

POLITEKNIK MANUFAKTUR NEGERI BANDUNG
Jl. Kanayakan no. 21, DAGO 40235, Tromol Pos 851 BANDUNG 40008 INDONESIA
Phone : 62 022 2500241 Fax : 62 022 2502649 Homepage : http ://www.polman-bandung.ac.id
e-mail : polman@melsa.net.id
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PREFACE
Assalamu’alaikum Wr. Wb.

Alhamdulillahirabbil'alamin, for the blessings of grace and grace from Allah, the author can
complete the writing of the Supervisory Distributed Control System Report.

The writing of this report is intended to account for and explain the explanation of the
Supervisory Distributed Control System Practicum that has been carried out. The author
realizes that the contents of this report are still lacking and far from perfect, this imperfection
is caused by the limited ability of knowledge and experience that the author has. Therefore, for
the sake of perfection, suggestions and criticisms from all parties that are constructive and
provide encouragement, the authors expect.

In carrying out this practicum, the writer cannot be separated from support and guidance from
various parties. On this occasion also, the author would like to thank Allah SWT for His grace
and guidance given to the author, Mrs. Pipit Anggraeni, ST., MT., Ph.D. as a lecturer, Mas
Ade, Kang Faishal Budikasih, Dhea Safitri as our Supervisor during the practice, also
colleagues absent from 3 AEDs who have provided support in practical activities and making
this Report. Hopefully their good deeds get a better reply from Allah SWT.

The writer really hopes that this writing can be useful especially for writers and generally for
readers.

Wassalamu’alaikum Wr. Wb.

Thursday, 7 November 2019

writer

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Table of Contents

PREFACE............................................................................................................................................... i
Table of Contents .................................................................................................................................. ii
CHAPTER 1 .......................................................................................................................................... 1
INTRODUCTION................................................................................................................................. 1
1.1 Background ............................................................................................................................. 1
1.2 Formulation of the problem .......................................................................................................... 2
1.3 Objective ................................................................................................................................. 2
CHAPTER 2 .......................................................................................................................................... 3
THEORETICAL BASIS ...................................................................................................................... 3
2.1 CIROS PROGRAMMING ........................................................................................................... 3
A. Definition Ciros Programming................................................................................................. 3
B. How to Installing Ciros ......................................................................................................... 4
CHAPTER 3 ........................................................................................................................................ 20
PRACTICUM RESULTS .................................................................................................................. 20
I. Project 1 conveyor............................................................................................................... 20
3) Creating the Workpiece ................................................................................................................ 25
5) Modeling the Trashcan.................................................................................................................. 42
6) Mechanism Trashcan .................................................................................................................... 42
7) Mechanism Replicator .................................................................................................................. 45
8) Setup Robot................................................................................................................................... 47
9) Programming the Robot ............................................................................................................. 49
II. Project 2 holder 1 box ..................................................................................................... 55
III. Project 3 Holder 3 Box...................................................................................................... 58
CHAPTER IV...................................................................................................................................... 61
CONCLUSION ................................................................................................................................... 61

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CHAPTER 1
INTRODUCTION

1.1 Background

Robotics is a subject that leaves nobody indifferent. No matter if they are used to work in
industry or at our homes, mimic some of the human capabilities, or used to access dangerous
environments, launched to space, or simply used to play with, robots are always a source of
interest and admiration. Here the focus is in robots used to work on industrial environments
robots built to substitute man on certain industrial manufacturing tasks being a mechatronic
coworker for humans. In fact, actual manufacturing setups rely increasingly on technology. It
is common to have all sources of equipment on the shop floor commanded by industrial
computers or PLCs connected by an industrial network to other factory resources. Also,
manufacturing systems are becoming more autonomous, requiring less operator intervention in
daily operations. This is a consequence of today's market conditions, characterized by global
competition, a strong pressure for better quality at lower prices, and products defined in part
by the end-user. This means producing in small batches, never risking long stocks, and working
to satisfy existing customer orders. Consequently, concepts like flexibility and agility are
fundamental in actual manufacturing plants, requiring much more from the systems used on
the shop floor. Flexible manufacturing systems take advantage of being composed by
programmable equipment to implement most of its characteristics, which are supported by
reconfigurable mechanical parts. Industrial robots are good examples of flexible manufacturing
systems. Using robots in actual manufacturing platforms is, therefore, a decision to improve
flexibility and to increase the agility of the manufacturing process. If the manufacturing
processes are complex, with a low cycle time, and have a lot of parameterization due to the
diversity of products, then using robots is the correct decision, although it isn't enough for a
complete solution. In fact, engineers need to Industrial Robots Programming integrate other
technologies with the objective of extracting from robots the flexibility they can offer. That
means using computers for controlling and supervising manufacturing systems, industrial
networks, and distributed software architectures. It also means designing application software
that is really distributed on the shop floor, taking advantage of the flexibility installed by using

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programmable equipment. Finally, it means taking special care of the humanmachine interfaces
(HMI), i.e., the devices, interfaces, and systems that enable humans and machines to cooperate
on the shop floor as coworkers, taking advantage of each other's capabilities

1.2 Formulation of the problem

1. What is CIROS software?

2. What is advantages and disadvantages in CIROS software?
3. How to make a simulation for integrating some devices in one system?
4. How to make a robot simulation?
5. How to adjusts a setting of CIROS software?

1.3 Objective

1. Make a simulation for integrating some devices in one system

2. Students can use installation CIROS software
3. Students learn about how to make a robot simulation
4. Students can understand a concept of CIROS Software
5. Students can make a reating sample programs for the models
6. Students can make a simulation how to make robot works
7. Students can create work cell simulation
8. Students can create sensor simulation
9. Students can create Controller selection
10. Students can adjust a setting in CIROS software

1.4 Method

Practice using CIROS software at FMS Lab.

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CHAPTER 2

THEORETICAL BASIS

2.1 CIROS PROGRAMMING

A. Definition Ciros Programming

Useful software for programming Mitsubishi robot systems with the following functionalities:

 Project wizard for selecting the robot configuration and detailed documentation of the projects
 Programming in MRL and Melfa Basic III, IV and and V with comprehensive online help
 Command lists tool with online communication for robot controlling
 Syntax check
 Online monitor of I/Os
 Upload and download of position lists and programs
 Parameterisation of the robot system data
CIROS® Programming is a Mitsubishi product which is included in the core of CIROS®
Studio.

System requirements

 PC with Windows 7, 8, or 10 (64 bits)

 At least Intel Core Duo 2.2 GHz Processor
 1 GB MB main memory
 10 GB free space on hard disk

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B. How to Installing Ciros

To install a CIROS® applica tion, we’ll need the DVD ROM for the CIROS® Automation
Suite. All software packages from the CIROS®Automation Suite can be installed from the
DVD ROM. The user manuals for the individual software packages are also included as PDF
documents. Licensing is carried out after installation has been finalised. You can start the
CIROS® application once licensing has been successfully completed. System requirements for
the CIROS® Automation Suite are specified below. System requirements for a Mechatronics
programming system have not been taken into consideration. A Mechatronics programming
system is required if you wish to create your own Mechatronics programs for the process
models. If you have purchased a single license, you can install the CIROS® application locally
to a PC. The PC must be equipped with a USB port in which the license dongle remains plugged
in during use of CIROS®.If you have purchased a multiple license, you’ll need a license server.
The license server manages your CIROS® licenses and makes them available to the individual
PC workstations within the network, to which CIROS® has been installed.

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Initial installation steps:

1) Switch on the PC and start Microsoft Windows.
2) Insert the CIROS® Automation Suite DVD ROM into the appropriate
drive.
3) The installation program for the CIROS® Automation Suite is started
automatically. If installation is not started automatically, double click the Start.exe
file on the DVD ROM.
4) The initial window of the CIROS® Automation Suite appears. Select
the language in which you want to install the CIROS® Mechatronics
application.

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5) Next you’ll be prompted to select the language in which the

installation instructions will be displayed. Confirm your selection
with Weiter

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6) Follow the instructions displayed by the installation program. If

you’re not certain how to answer any of the questions, click Back or
Cancel.

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7) First of all, you’re familiarised with Festo Didactic’s license

agreements. You must accept these license agreements in order to
be able to continue with installation of the application. Click I agree
to the terms of this license agreement, and then click the Next
button

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8) Select the subdirectory to which CIROS® Mechatronics will be

installed in the Installation Folder window. The following
subdirectory is automatically selected as a default location:
C:\Programme\didactic\CIROS Automation Suite 1.1\CIROS
Mechatronics.en.

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If you want to install the software to a different directory, click the

Change button.
9) You can also select a program group to which the CIROS® Mechatronics icons will be
saved. The following program group is selected automatically as a default value: Festo
Didactic\CIROS Automation Suite EN\CIROS Mechatronics. This selection can be
changed if desired. You are subsequently provided with the option of installing the
software for the currently logged on user only.
10) Select the language of the Assistant. CIROS® Mechatronics is now ready to be installed.
Click the Start button to begin installation.

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11) Start installation by clicking the Next button.

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12) Follow the instructions displayed by the installation program. A

default subdirectory is preselected for installation. The Everyone
user group is preselected as the user of OPC components.
If you want to use these default settings, click the Next button.

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13) You must accept the license agreement in order to be able to

continue with installation. Make the appropriate selection and then
click the Next button

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14) . A corresponding message appears after the OPC components have

been successfully installed. Click the Close button.

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15) A corresponding message appears after CIROS® Mechatronics has

been successfully installed. Click the Finish button

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CHAPTER 3

PRACTICUM RESULTS

I. Project 1 conveyor

This is intended to make you familiar with some basic procedures while working with CIROS.
It goes beyond the content of the Getting Started tutorial and has been written for users who
have already basic experience in working with CIROS. It is assumed that you have already
read and worked with the Getting Started when beginning with this example.

The main intent is to provide information on how to add and handle mechanisms as well as
how to handle the most frequent graphical modeling tasks.

covers:

Usage of materials
Usage of mechanisms
Conveyor belt
Replicator
Trashcan
Modeling of templates
Modeling of primitive, inactive objects
Usage of sensor types
 Distance sensor
 Color sensor
Utilization of the information given by the sensors to
 control the conveyor belt
 move the robot relatively
 sort items by color
Randomized creation of simple objects

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1) Create a new model and add the robot from the Robots > Demo library. Save the model
as Tutorial.mod

2) Adding a Conveyor Belt

Open the Model Libraries and add ConveyorBelt from the ModLibs > Conveyors
library.

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The added conveyor belt has two inputs which can be used to control the state (on/off) and the
direction of the transportation mechanism. To switch the belt on, the input OnOff must be set
to 1. By default the conveyor belt transports items from the drive to the end. Backwards=1
changes the transportation direction. The output PartAtEnd indicates whether an object has
reached the end of the conveyor belt.

The mechanism "grasps" any grip point that touches the conveyor surface and transports the
corresponding object until the grip point reaches the conveyor's end. As soon as an object
reaches the end, the output PartAtEnd will be set to 1.

 Scaling the conveyor belt:

The conveyor is modeled in a way that it can be scaled by the Assembly scaling extension.
Open its Assembly scaling property page and use the spin controls to scale the conveyor to the
valued displayed below:

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 Positioning of the conveyor belt:

After importing, the conveyor belt is positioned in the origin of the model's coordinate system.
The conveyor belt shall be turned by 90°, and then moved so that the end of the belt is
positioned in the workspace of the robot. Select the Conveyor belt in the Model Explorer and
open the Properties dialog. There, select the Pose tab and choose Coordinate system World.

Turn the object by reducing the absolute roll angle to -90°. Then move the object to the x,y,z
coordinates given in the following picture:

Finally, model should look like this:

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3) Creating the Workpiece

In this step, wecreate a simple workpiece from a geometric primitive. The workpiece shall
have the following properties:

 Box shaped, 150mm x 150mm x 150mm size

 Grip point on the bottom, so that the workpiece can be grasped by the conveyor belt.
 Grip point on the top, so that it can be grasped by the robot.

1
2

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 Creating a simple workpiece using the Model Explorer:

In the Model Explorer, select the Objects entry. Use Command New > Object from the
context menu to create a new object. Rename the new object to BoxBlue.

The new object ist positioned in the origin of the world coordinate system. To make sure that
you can see it during further modeling, move the object e.g. to world coordinates x,y,z =
1000mm, 0mm, 0mm.

Go to its Mechanism property page and check the Object is a Workpiece / Tool of the
Mechanisms option.

For the new object select command New > Section from the context menu to create a new
section. The section is automatically named Base

In the section, create a new box in the same way (New > Geometric Primitives > Box).

Select the box and use the property tab General to enter new values for Length x,y,z =
150.00mm.

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Then select the Visualization tab to change the color to blue.

 Adding grip points:

To add grip points to the box, select the section base. Then use command New > Grip Point
from the context menu twice to add two grip points. Rename the first grip point to GPTop, the
second to GPBottom.

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The grip point GPTop shall be placed in the middle of the top surface where it can be grasped
by the robot's gripper, the replicator and the trashcan. Move the grip point in the section
(Coordinate system: Section) to x,y,z = 75mm, 75mm, 150mm.

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Leave the grip point GPBottom at position x,y,z = 0mm. The grip point is located at the bottom
of the box (where it can be grasped by the conveyor belt) and at the edge which first reaches
the conveyor's end.

Model should now look like this:

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4) Modeling the Replicator Socket

A replicator is a pure mechanism without any visualization. To avoid items that appear just out
of nothing, a simple socket for the replicator has to be modeled. Later the replicator will be
placed into the socket.

Creating the socket:

Create a new object and rename it to ReplicatorSocket. Move the object to position x,y,z =
500mm, 1400mm, 0mm. Then create a new section and a new box inside the section.

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Assigning a material:
Open the Model Libraries and add the material SmokyGlass from the ModLibs > Materials
library. Then select the object ReplicatorSocket in the Model Explorer and drag it to the entry
of the material SmokyGlass

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The properties of the surface are now corresponding to the properties of the material
SmokyGlass. The surface will become e.g. semi transparent.

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Deleting unneeded Facets:

Execute Settings > Options to open the Options dialog command and go to the Model
Explorer page. There, check the Facets filter in order to show facets in the Model Explorer.
Close the Options dialog.

Select the facets number 3 and 4 of the box (the bottom and the facet which is pierced by the
conveyor belt).

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Use command delete from the context menu to delete the selected facets.

Select the box and execute the Edit > Add backface command from its context menu. This
command adds an inverted facet for each facet in order to make them visible from the back /
inner side.

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Model should now look like this:

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5) Modeling the Trashcan

Similar to the replicator, the trashcan does not have any visualization. For visualization
purposes, a geometric primitive will be added and modified:

Create a new object and rename it to Trash. Add a section and a cylinder. Open the general
properties of the cylinder and change the following properties: Radius = 200mm, Height =
500mm.

Move the object Trash to a position where it can be reached by the robot, (x,y,z = -100mm,
1100mm, 0mm) and assign the material SmokyGlass to the object.

6) Mechanism Trashcan

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Open the Model Libraries and add the mechanism Trashcan from the library Modeling
Essentials > Abstraction.

 About the mechanism:

The mechanism Trashcan is equipped with three gripper points. Each of them is assigned to
an input. If an object is "grasped" by one of the gripper points, it will be deleted from the
model.

If an object's grip point is in the range of the mechanism's gripper point, the object can be
deleted by setting the corresponding input from 0 to 1.

 Adding the mechanism to object Trash:

Select the object TrashCan. Use the pose tab of the dialog Properties for Object to move the
object to the x- and y-coordinates of object Trash (World x,y = -100mm, 1100mm). Choose
z = 500mm. The mechanism is now placed in the middle of the top surface of object Trash.

Then select the object TrashCan in the Model Explorer and drag it to object Trash. After
releasing the mouse button, the mechanism becomes a part of object trash. It is displayed as
a child entry of object Trash in the Model Explorer.

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7) Mechanism Replicator

 About templates:

Templates are construction plans for objects. Similar to objects, they have an own entry in
the top level of the Model Explorer.

To create a template, just model the desired object, and then drag the object to the templates
entry using the Model Explorer. The object will then be removed from the model, and a
corresponding construction plan will be added to the templates section.

To provide replication of objects on base of a template, the object/template must have at least
one grip point.

 About the replicator mechanism:

The Replicator mechanism provides the ability to generate objects based on templates. The
names of the templates can be added to the extended properties of a replicator object.

To create an object based on a template, the input of the replicator which is corresponding to
a template has to be set from 0 to 1. The object will then be created and added to the model
at the replicator's gripper point.

Replicators can be added in two different ways:

·Adding from the model library Modeling Essentials > Abstraction:

A replicator added from the model library is added at the origin of the world coordinate
system and has to be configured manually.

·Adding via the context menu of an object (Edit > Create replicator):
When creating a replicator this way, the replicator will be created at the first grip point of the
selected object. The replicator will be automatically configured to create the selected object
at its original pose. The object itself will be moved to the templates section.

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 Adding a replicator:

For this example, use the second way of adding a replicator: First move the object BoxBlue
to the position at which it shall later be replicated. Move it to the drive side of the conveyor
on the inside of the replicator socket (World coordinates x,y,z = 685mm, 1400mm, 500mm).

Now select the object BoxBlue in the Model Explorer and execute command Edit > Create
replicator from the context menu. The object BoxBlue will be removed from the model, and a
corresponding construction plan will be added to the templates section. At the same time, a
new object ReplicatorBoxBlue is created. Add the object ReplicatorBoxBlue to the object
ReplicatorSocket.

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8) Setup Robot

 Adding the gripper:

The replicated objects have a grip point in the center of their top which shall be grasped by a
vacuum gripper. Open the model library Grippers > Vacuum Gripper and add the gripper
Vacuum Gripper to your model.

 Renaming and activating I/Os:

The robots needs a number of I/Os to control the mechanisms and the gripper. Digital outputs
are needed to grasp an object, to trigger the replicator, to start the conveyor belt and to destroy
objects in the trashcan. Additionally, the robot needs at least one digital input which indicates
whether an object has reached the conveyor belt's end. Use the Model Explorer to rename the
I/Os of the robot as shown in the following image. By renaming an I/O, it is automatically
activated:

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Note:

For Mitsubishi robots the I/Os for gripper control are fixed and pre-defined. Instead of Grasp
use the predefined output HCLOSE1.

 Connecting inputs and outputs:

Open the Manual Operation window (Modeling > Manual Operation). Connect the I/Os of the
robot with the corresponding I/Os of the mechanisms and the gripper. The following image
shows the required connections. In the screenshot below, some columns of the Manual
Operation window have been hidden. To show/hide elements of the window, use the
corresponding commands from the window's context menu.

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The robot can now control the mechanisms and the gripper by setting or resetting digital
outputs. A positive signal at input ItemAvailable indicates that an object has reached the end
of the conveyor belt.

9) Programming the Robot

Position list:

To program the robot, three positions are required: The initial position of the robot, the
picking position at the end of the conveyor belt and the placing position at the trashcan. Create
a new position list, and add the initial position of the robot three times.

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 Picking position:

Since the boxes are replicated with their first grip point at world coordinates x,y,z = 760mm,
1475mm, 650mm, and then only moved in y-direction, the x and z coordinates for the picking
position are fix. When the box stops at the conveyors end, the upper gripper point is at y = -
60mm.

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 Placing position:

The world coordinates of the trashcan's gripper point are x,y,z = -100mm, 1100mm, 500mm.
Since the gripper point of the mechanism shall "grasp" the box at the upper grip point, these
are also the coordinates for the placing position.

Create an object Set output replicate from 0 to 1

Switch on conveyor belt Set output StartStop = 1

Wait until item at end Wait until input ItemAvailable = 1
Switch off conveyor belt Set output StartStop = 0
Move to picking position Move to position 50mm above the grip point,
then move straight to the grip point
Grasp Set output Grasp = 1

(Mitsubishi: Command HCLOSE1)

Move to placing position Move up straight, then move to a position
200mm above the trashcan and move down
straight to the placing position
Open gripper Set output Grasp = 0

(Mitsubishi: Command HOPEN1)

Remove object from trashcan Set output remove from 0 to 1

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II. Project 2 holder 1 box

1. Choose command New Work cell from the File menu to create a new
work cell. Specify the filename (e. g. “Example. mod”) for the new work
cell. After creating the new work cell you are able to specify a different work
cell name as well as properties for the work cell (e. g. background color,
floor color, and floor size).
2. Edit the element properties in dialog box Properties for object as
follows: Pose (x,y,z) 750 mm, -250 mm, 0 mm Dimension (x,y,z) 250 mm, 500 mm,
500 mm Visualization Light blue In the Model Explorer rename the object “Box” to
“Table”.
3. Add a second box to your work cell. Rename it by MyBox and edit the
element properties in dialog box Properties for object as follows: Pose (x,y,z) 850 mm,
0 mm, 500 mm Dimension (x,y,z) 50 mm, 50 mm, 50 mm Visualization Light grey

4. To let a work piece be grasped by a robot you have to assign a grip

point to the work piece. Select the group base of the object MyBox and
open the context menu. Choose the command New -> Grip point.
Rename the grip point to Workpiece and move the grip point in the
centre of the object by choosing following coordinates relative to the section coordinate
system: Pose (x,y,z) 25 mm, 25 mm, 25 mm (R,P,Y) 180 °, 0 °, 180 °

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Select the Parallel Gripper (simple) of library “Miscellaneous Grippers”

in dialog box Model Libraries and click Add. The gripper is attached to
the robot’s flange automatically.

5. To simulate the electrical connection between the robot controller and

the gripper, select the menu command Modeling -> Manual Operation to
open the window Manual Operation:

6. Position

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7. Programming

III. Project 3 Holder 3 Box

1. Object

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2. Position

3. Programming

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4. Results

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CHAPTER IV
CONCLUSION

CIROS is the professional tool for creating simulation models. Used by industry, this
powerful development platform unites, in one common interface, three essential tools
Simulation, Modeling, and Programming.
In Distributed Control System 2 , I learn how to Make a simulation for integrating some
devices in one system i learn about how to make a robot simulation, concept of CIROS
Softwar we can make a reating sample programs for the models we make a simulation how
to make robot works we can create work cell simulation we can create sensor simulation
we can create Controller selection Students can adjust a setting in CIROS software

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