Prolog Manual A003

ProLog®
Manual
Festo Didactic
ProLog
07/2015
Order-No.:
Date: 07/2015
Layout: 07/2015, Schober
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2015
Internet: www.festo-didactic.com
E-Mail: did@de.festo.com
Reproduction, distribution and utilisation of this document, as well as the communication of its contents to
others without explicit authorisation, are prohibited. Offenders shall be held liable for payment of damages.
All rights reserved, in particular the right to file patent, utility model and registered design applications.
Note
Where only pronouns such as he and him are used in this manual, these pronouns are of course
intended to refer to both male and female persons. The use of a single gender should not be
construed as gender discrimination; it’s intended solely to make the manual easier to read and the
formulations easier to understand.
Intended use
This installation was developed and manufactured for use in basic and further training in the fields
of automation and communications. The training company and/or the training staff must ensure
that the trainees observe the safety precautions described in the accompanying manuals.
Furthermore this manual describes setup and possible uses of the singular stations. It contains all
information and data required for commissioning, maintenance and operation.
Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any
third parties occurring when the installation is used for any purpose apart from training, except
Festo Didactic has caused such injury or harm intentionally or by grossly negligence.
2 © Festo Didactic ProLog

Content
1 General safety instructions __________________________________________________________________ 6

1.1 Pictograms ___________________________________________________________________________ 7
1.2 Safety sockets_________________________________________________________________________ 8
1.3 Handling the system ___________________________________________________________________ 9
1.3.1 Dangers in handling the machine _____________________________________________________ 9
1.3.2 Safety precautions in standard operation ______________________________________________ 9
1.3.3 Dangers due to electric current _______________________________________________________ 9
1.3.4 Dangers due to pneumatic energy ___________________________________________________ 10
1.3.5 Maintenance – Servicing – Malfunction removal ________________________________________ 10
1.3.6 Organizational measures ___________________________________________________________ 10
1.4 Personnel ___________________________________________________________________________ 10
1.4.1 Notes on personnel ________________________________________________________________ 10
1.4.2 Training operations ________________________________________________________________ 10
1.4.3 Outside training operations _________________________________________________________ 10
1.4.4 Obligations of the operating company ________________________________________________ 10
1.4.5 Obligations of the trainees __________________________________________________________ 10
2 Introduction _____________________________________________________________________________ 11
2.1 Warranty and liability __________________________________________________________________ 11
2.2 Intended use _________________________________________________________________________ 11
2.3 Important notes ______________________________________________________________________ 11
2.4 General _____________________________________________________________________________ 12
2.5 Customer system _____________________________________________________________________ 13
2.5.1 Triple stack magazine station _______________________________________________________ 14
2.5.2 Testing station with color sensor _____________________________________________________ 15
2.5.3 Processing station_________________________________________________________________ 16
2.5.4 Pick and place station ______________________________________________________________ 17
2.5.5 Fluid muscle station _______________________________________________________________ 18
2.5.6 Storing station ____________________________________________________________________ 19
2.5.7 Separating station_________________________________________________________________ 20
2.5.8 Sorting station ____________________________________________________________________ 21
2.5.9 Commissioning station _____________________________________________________________ 22
2.5.10 Log area ________________________________________________________________________ 23
2.5.11 Robotino 1&2 ___________________________________________________________________ 24
2.6 System ______________________________________________________________________________ 25
2.7 Didactic structure _____________________________________________________________________ 26
3 Commissioning __________________________________________________________________________ 28
3.1 Transport ____________________________________________________________________________ 28
3.1.1 Unpacking _______________________________________________________________________ 28
3.1.2 Scope of delivery __________________________________________________________________ 28
3.2 Set up ______________________________________________________________________________ 29
3.2.1 General information _______________________________________________________________ 29
3.3 Commissioning _______________________________________________________________________ 30
3.3.1 Pneumatic commissioning __________________________________________________________ 30
3.3.2 Electric commissioning _____________________________________________________________ 31

3.3.3 Connecting communication cables ___________________________________________________ 31
4 Operation _______________________________________________________________________________ 36
4.1 General operation notes _______________________________________________________________ 36
4.1.1 Behaviour rules ___________________________________________________________________ 36
4.1.2 Operation rules ___________________________________________________________________ 36
4.2 Process description ___________________________________________________________________ 36
4.2.1 Material flow _____________________________________________________________________ 37
4.3 Robotino information and operation _____________________________________________________ 39
4.3.1 General __________________________________________________________________________ 39
4.3.2 Start up _________________________________________________________________________ 40
4.3.3 Switch off the robotino _____________________________________________________________ 40
4.4 Program start ________________________________________________________________________ 41
4.5 Robotino Startup _____________________________________________________________________ 42
4.5.1 Project upload ____________________________________________________________________ 44
4.5.2 Sequence to collect one Palette _____________________________________________________ 45
4.6 Robotino-Pro-Log _____________________________________________________________________ 50
4.6.1 Init Subprogram __________________________________________________________________ 56
4.6.2 Explanation ______________________________________________________________________ 56
4.6.3 Sequence to collect one Palette _____________________________________________________ 57
4.6.4 Global Variables __________________________________________________________________ 58
4.7 Data Exchange Variables _______________________________________________________________ 59
4.8 Log area information and operation ______________________________________________________ 60
4.8.1 General __________________________________________________________________________ 60
4.8.2 Start up log area __________________________________________________________________ 62
4.9 Start up MPS stations _________________________________________________________________ 63
4.9.1 Requirements ____________________________________________________________________ 63
4.9.2 Reset process of MPS-stations ______________________________________________________ 63
4.10 Start up commissioning station ________________________________________________________ 64
4.10.1 Requirements ___________________________________________________________________ 64
4.10.2 Reset process robot station ________________________________________________________ 64
4.11 Default mode _______________________________________________________________________ 65
4.12 MES Mode __________________________________________________________________________ 66
5 WinCC __________________________________________________________________________________ 67
5.1 System information ___________________________________________________________________ 67
5.1.1 Start-up WINCC ___________________________________________________________________ 67
5.2 Use Runtime Application _______________________________________________________________ 68
6 Process description _______________________________________________________________________ 75
6.1 Triple stack magazine _________________________________________________________________ 75
6.1.1 Standalone mode of Triple stack magazine ____________________________________________ 75
6.1.2 MES mode of Triple stack magazine __________________________________________________ 76
6.2 Testing Station _______________________________________________________________________ 78
6.2.1 Standalone mode of Testing Station __________________________________________________ 78
6.2.2 MES mode of Testing Station ________________________________________________________ 80
6.3 Processing Station ____________________________________________________________________ 82
6.3.1 Standalone mode of Processing Station _______________________________________________ 82
6.4 Pick & Place Station ___________________________________________________________________ 84
6.4.1 Standalone mode of Pick & Place Station ______________________________________________ 84

6.5 Fluidic Muscle Press Station ____________________________________________________________ 86
6.5.1 Standalone mode of Fluidic Muscle Press Station _______________________________________ 86
6.6 Storing Station _______________________________________________________________________ 88
6.6.1 Standalone mode of Storing Station __________________________________________________ 88
6.6.2 MES mode of Storing Station ________________________________________________________ 92
6.7 Separating Station ____________________________________________________________________ 98
6.7.1 Standalone mode of Separating Station _______________________________________________ 98
6.7.2 MES mode of Separating Station ____________________________________________________ 100
6.8 Sorting Station ______________________________________________________________________ 102
6.8.1 Standalone mode of Sorting Station _________________________________________________ 102
6.9 Robot Station and Robotinos __________________________________________________________ 103
6.9.1 Standalone mode of Robot Station and Robotinos _____________________________________ 103
6.9.2 MES mode of Robot Station ________________________________________________________ 107
6.9.3 MES mode of Robotino 1 __________________________________________________________ 113
6.9.4 MES mode of Robotino 2 __________________________________________________________ 116
7 Technology _____________________________________________________________________________ 118
7.1 drawings ___________________________________________________________________________ 118
7.2 Modules in use ______________________________________________________________________ 119
7.2.1 Pallet __________________________________________________________________________ 119
7.2.2 Work pieces _____________________________________________________________________ 119
8 Pneumatic ______________________________________________________________________________ 120
8.1 Pneumatic supply ____________________________________________________________________ 120
9 Electrical System ________________________________________________________________________ 121
9.1 Power supply _______________________________________________________________________ 121
9.2 Controller __________________________________________________________________________ 122
9.3 Wiring _____________________________________________________________________________ 123
9.3.1 I/O-Components _________________________________________________________________ 123
© Festo Didactic ProLog 5

1 General safety instructions
The laboratory or the classroom must be equipped in accordance with EN 50191:
 An emergency off device must be provided.
– At least one emergency off device must be located within, and one outside of the test area.
 The test area must be secured against unauthorised start-up.
– For example with a key switch
 The test area must be protected by residual current devices (RCDs).
– Type B residual current circuit breaker with a residual current rating of ≤ 30 mA
 The test area must be protected by overcurrent protection devices.
– Fuses or circuit breakers
 The test area must be overseen by a supervisor.
– A supervisor is a qualified electrician or a person who has received appropriate instruction, has
knowledge of the respective safety requirements and safety regulations and whose training has been
accordingly documented.
 No damaged or defective devices may be used.
– Damaged devices must be barred from further use and removed from the test area.
General requirements for safe operation of the devices:

 Do not lay cables over hot surfaces.
– Hot surfaces are identified with a corresponding warning symbol.
 Maximum permissible current loads for cables and devices must not be exceeded.
– Always compare the current ratings of the device, the cable and the fuse.
– In the event that these are not the same, use a separate upstream fuse in order to provide
appropriate overcurrent protection.
 Devices with an earth terminal must always be grounded.
– If an earth connection (green-yellow laboratory socket) is available, it must always be connected to
protective earth. Protective earth must always be connected first (before voltage), and must always be
disconnected last (after voltage).
 If not otherwise specified in the technical data, the device is not equipped with an integrated fuse.

General safety instructions
1.1 Pictograms
This document and the described hardware include warnings concerning possible hazards which may arise if
the system is used incorrectly. The following pictograms are used:
Warning
Non-observance of this pictogram may result in serious personal injury or damage
to property.
Caution
Non-observance of this pictogram may result in personal injury or damage to
property.
Warning
This pictogram indicates that the device must be switched off and its mains plug
must be removed from the electrical outlet before installation, repair, maintenance
and cleaning work. Observe the manual, in particular all safety instructions. Non-
observance may result in severe personal injury or damage to property.
Warning
This pictogram indicates danger of being burned if hot surfaces (up to roughly
85 C) are touched.
Important
This symbol emphasizes important information for correct machine handling.
Failure to pay attention to this symbol may result in damages to the machine or to
its surroundings.
i
Information
This symbol indicates operational tips and especially useful directions. This
symbol assists you to make optimal use of all of your machine’s functions.

1.2 Safety sockets

If not otherwise specified in the technical data, the following colour codes apply to the power supply and
signal connections for components included in Festo Didactic’s learning system for automation and
technology.
Colour Function Colour Function
Voltage greater than SELV 24 V DC

e.g. line voltage of 90 to 400 V AC per conductor (red)
(grey)
Neutral conductor 0 V DC
(blue) (blue)
Protective conductor Safety extra-low voltage,

(green-yellow) signal input/output
(black)
The specified protection class and safe use can only be assured if laboratory safety cables supplied by Festo
Didactic are used.
 Warning
Damaged laboratory safety cables must be immediately barred from further use and
removed from the test area.

1.3 Handling the system

1.3.1 Dangers in handling the machine
The installation has been constructed technologically up to date and in conformance with the recognized
rules of safety engineering. Nevertheless, during operation it is possible that harm might be caused to the
user or third parties or that the installation or other property might get damaged. Therefore, the installation
has to be handled according to specified operational use in perfect technical condition only.
Safety endangering malfunctions cannot be tolerated during training and have to be removed immediately.
The system is to be used only:
 for its intended purpose and
 In absolutely safe conditions.
Warning
Faults impairing safety must be rectified immediately!
1.3.2 Safety precautions in standard operation

Put the installation into operation only, once all of the protection settings are completely functional.
At least, before starting operation, check the installation for externally visible damages and for the reliability
of the safety devices.
Do not grip into the installation while in operation.
Before circuit construction, circuit disassembly and circuit modification: switch off air pressure and power
supply.
General safety regulations are to be observed: DIN 58126 and VDE 0100.
1.3.3 Dangers due to electric current

As soon as maintenance is completed, check the function reliability of the safety devices.
Only trained experts in electric or electronic engineering are permitted to carry out work on the electric
supply system.
The terminal boxes are to be kept closed at all times. Access must be permitted only under supervision of a
member of the training staff.
Do not activate electric limit switches manually during fault search. Tools are to be used.
Only low voltage 24VDC is to be used.

1.3.4 Dangers due to pneumatic energy

Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt air pressure supply
immediately. Caution! When the air pressure supply is activated, cylinders may move in or out.
Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In this case, keep on holding
the end of the tube. Do not exceed the permitted operating pressure. See data sheets.
1.3.5 Maintenance – Servicing – Malfunction removal

Carry out adjustments and inspections as instructed, in accordance with the specified intervals.
Secure the compressed air and electricity supplies to prevent unintentional start-up.
During inspections, maintenance and repair work, the machine must be de-energized, de-pressurized and
secured against unexpected restart. All screw connections released during maintenance, inspection or
repair work must be checked to ensure correct re-tightening.
1.3.6 Organizational measures

All existing safety devices must be checked at regular intervals.
1.4 Personnel
1.4.1 Notes on personnel
Basically two situations have to be considered, concerning matters on personnel.
 Activities during training operations
 Activities outside training operations
1.4.2 Training operations

Trainees are permitted to work with the machine only under strict supervision of an experienced person or
an instructor.
Activities of trouble-shooting and fault correction are to be checked by the instructor. Special care should be
taken regarding safety aspects.
1.4.3 Outside training operations

Activities in the areas of maintenance, service and repair are to be carried out by only persons with
appropriate technical qualifications.
1.4.4 Obligations of the operating company

The operating company undertakes to allow only those persons to work with the system who:
 Are familiar with the basic regulations regarding work safety and accident prevention and have been
instructed in the use of the system
 Have read and understood the chapter concerning safety and the warnings in this manual
Personnel should be tested at regular intervals for safety-conscious work habits.
1.4.5 Obligations of the trainees

All persons who have been entrusted to work with the system undertake to complete the following steps
before beginning work:
 Read the chapter concerning safety and the warnings in this manual

2 Introduction
2.1 Warranty and liability
In principle all our „Terms and Conditions of Sale“ apply. These are available to the operating authority
upon conclusion of the contract at the latest. Warranty and liability claims for persons or material damage
are excluded if these can be traced back to one or several of the following causes:
 Use of the system not in accordance with its intended purpose
 Incorrect assembly, commissioning, operation and maintenance of the system
 Operation of the system using faulty safety equipment or incorrectly fitted or non-operational safety or
protective devices

Non observance of notes in the manual regarding transport, storage, assembly, commissioning,
operation, maintenance and setting up of the system
 Unlawful constructional modifications on the system
 Inadequate monitoring of components subject to wear
 Incorrectly carried out repairs
 Catastrophes as a result of foreign bodies and vis major.
Festo Didactic herewith rules out any liability for damage or injury to trainees, the training company and/or
other third parties which may occur during the use/operation of the system other than purely in a training
situation, unless such damage has been caused intentionally or due to gross negligence by Festo Didactic.
2.2 Intended use

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

The basic requirement for safe use and trouble-free operation of the system is to observe the fundamental
safety recommendations and regulations.
This manual contains important notes concerning the safe operation of the system.
The safety recommendations in particular must be observed by anyone working on the system.
Furthermore, the rules and regulations for the prevention of accidents applicable to the place of use must be
observed.

Introduction
2.4 General
In the development of the system, various production technologies have been combined into one
installation. The aim of the installation is the increase of competence, from a simple setting of examples up
to a complete production process, including all features.
Additionally, to technical and social competence, the comprehension of the process and the interaction of
the respective components appear in clear presentation.
This manual describes working with the ProLog-factory system. Everything is explained and described for
the operation of necessary events. With the help of graphics or pictures a simple communication should be
obtain.
Complete operating instructions which explain the processes of the system are available for working with
the system. Station manuals are also available for the individual stations.
Festo Didactic succeeded in using the most updated industrial hard- and software for this model production.
The ProLog Factory consists of 3 main areas:
 The Production Line, where the products are produced
 The Commissioning station, where the customer orders are picked
 The Warehouse Area, where the customer orders (pallets) are buffered until delivery
The production line itself consists of up to 8 MPS Stations. Each Station has its own controller to support a
decentralized control structure.
The Commissioning Station consists of a 6 axis robot. The customer orders are completed according the
order data in this station. After completion, the pallets (orders) are put to the warehouse input slide.
The warehouse is served by mobile robots. The mobile robots receive their transport orders from the MES4
according to the warehouse management data.
They move
 Empty pallets to the commissioning robot
 Completed orders from the warehouse input slide to the high-bay storage
 Deliveries from the storage to the warehouse output slides

Introduction
2.5 Customer system
Overview prolog-factory system
Position Description Position Description
1 Triple stack magazine station 8 Sorting station
2 Testing station with colour sensor 9 Log area
3 Processing station 10 Robotino 2
4 Pick and place station 11 Robotino 1
5 Fluid muscle station 12 Commissioning station
6 Storing station 13 Connecting conveyor 3
7 Separating station

Introduction
2.5.1 Triple stack magazine station
Triple stack magazine station
The triple stack magazine station separates workpieces from 3 magazines. Up to eight workpieces are
stored in each of the magazine tubes of the stacking magazines. A double-acting cylinder pushes the
workpieces out one at a time directly to the transfer point of the downstream station.

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

Introduction
2.5.3 Processing station
Processing station
In the Processing station, work pieces are tested and processed on a rotary indexing table. This station only
uses electrical drives. The rotary indexing table is driven by a DC motor. The table is positioned by a relay
circuit, with the position of the table being detected by an inductive sensor. On the rotary indexing table, the
work pieces are tested and drilled in two parallel processes. A solenoid probe with an inductive sensor
checks that the work pieces are inserted in the correct position. During drilling, the work piece is clamped by
a solenoid actuator. Finished work pieces are passed on via the electrical sorting gate.

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

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

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

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

Introduction
2.5.8 Sorting station
Sorting station
The Sorting station sorts work pieces onto three slides. Work pieces placed on the start of the conveyor are
detected by a diffuse sensor. Sensors upstream of the stopper detect the work piece features (black, red,
metal). Sorting gates actuated by short-stroke cylinders via a deflector allow sorting of work pieces onto the
appropriate slides. A retro-reflective sensor monitors the level of the slides.

Introduction
2.5.9 Commissioning station
Commissioning station
The commissioning station commissions work pieces from a conveyor on pallets. Empty pallets are moved
from the input slide to the buffer positions on the station. The commissioned pallets are moved to the
output slide for further use. The complete handling of pallets and work pieces is done be the robot.

Introduction
2.5.10 Log area
Log area
The log area is a logistic field of 2x2m. The high bay racking is used to buffer up to 6 pallets. There are 3
slides for the output of the pallets. Each of these slides is equipped with a RFID Sensor. A further slide for
the input of empty pallets is available.
The slides to the commissioning station are to supply the commissioning station with empty pallets and to
take the equipped pallets from.
2 robotinos are responsible for the handling of the pallets.

Introduction
2.5.11 Robotino 1&2
Robotino
The 2 robotinos are equipped with a lifting system to lift and lay down the pallets from and to the slides.
The task of the first robotino is to move the pallets from the output slide of the commissioning station to the
high bay racking and to pick up the empty pallets from the input slide of the log area and move them to the
input slide of the commissioning station.
The task of the second robotino is to move the pallets from the high bay racking to the 3 outputs slides from
the log area.

Introduction
2.6 System
Overview prolog-factory system
Position Description Position Description
1 Triple stack magazine station 8 Sorting station
2 Testing station with colour sensor 9 Log area
3 Processing station 10 Robotino 2
4 Pick and place station 11 Robotino 1
5 Fluid muscle station 12 Commissioning station
6 Storing station 13 Connecting conveyor 3
7 Separating station

Introduction
2.7 Didactic structure

The installation is structured, to enable methodical learning, i.e. from single use of modules to the complex
and complete installation. Perhaps even in combination with further systems.
For example, it is possible to pick out a single module to start with the first steps, e.g. the robot.
 First the mechanical assembly is considered. The robot’s radius of action requires integration into the
location of the robot.
 The following step could be the connection of all cables required for operation and the set-up of the
robot.
 Moving the robot and teaching the required positions are the first real operations with the robot, which
introduces the user how to deal with the teach-box.
 The robot’s programming can be started, as soon as the robot can be moved by the teach-box. Small
programs, which can be created by using the Cosimir/Cosirob software, are expandable for the complex
programs.
 Orders to further stations and from other controls can be installed in the programs.
Once the learning process of this module has been concluded, these learning steps can be transferred to the
next module. As soon as all of the modules have been processed individually, the modules can be
interconnected and the programs can be adapted. A complete production process can be simulated.
This is an ideal training area for the professional practice of mechatronics, as well as all of the technical
ranges (mechanical, electrical and pneumatic processes) are represented in a simple and clearly way,
concerning each one of the modules and the complete system.
The installation permits to face students to the reality of manufacturing processes by allowing them to apply
individual technologies already taught in the preliminary phases of engineering studies. Thus, each
technology is considered first separately and then combined together to optimize the manufacturing
processes.
Training contents covering the following subjects can be taught:

Mechanic:
 Adjusting of a handling system
 Assembly of singular station
 Using mechanical interfaces
Electronic:
 Wiring and testing electrical components
 Reading and designing electrical circuit diagrams
 Getting familiar with electrical drives
 Working with electrical interfaces
Robotic:
 Use of industrial robots
 Fundamentals of robot technology
 Robot programming

Introduction
Sensoric:
 Using limit switches and sensors
 Getting to know different types of sensors (inductive, optical, capacitive, analogue)
Pneumatic:
 Professional tubing of pneumatic components according to circuit diagrams
 Getting to know and using pneumatic components (different cylinders, valves, grippers)
 Using vacuum technology
Ident system:
 Getting familiar with the Identification system
 Data processing via Ident and PLC
PLC:
 Getting to know the structure and mode of operation of a PLC
 Programming a PLC in different PLC languages
 Interfacing a PLC to a Robot Controller and a visualization system
 Getting to know special function modules for positioning, counting
Vision system
 Collect and process from measure datas and analogue values with a PLC
 to become acquainted and work with a vision testing system
 To become acquainted with lightsystems
 To become acquanted with lens charactes
 Flash synchronisation
 Programming a vision testing system
Maintenance and Troubleshooting:

 Locating and rectifying faults and malfunctions
 Optimizing automated systems
Commissioning:
 Adjusting mechanical and electrical components
 Adjusting sensors and limit switches in automated systems
 Commissioning systems by means of a PLC

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

Check the scope of delivery against the delivery note and the order. Festo Didactic must be notified
immediately of any discrepancies.

Commissioning
3.2 Set up
3.2.1 General information
The installation is to be set up in a frost-free room with maximum relative air humidity of 70%. In countries
with an atmospheric humidity over 70% and temperatures above 25 degrees Celsius are the premises to
provide an air-conditioning system for constant surroundings conditions.
To comply with the regulatory guidelines, sources of electrical interference such as welding plants, large
motors and contactors are to be checked for electromagnetic compatibility in advance and screened where
necessary.
To ensure fault-free operation a load-bearing floor is required to avoid settling.
Allow sufficient distance between the installation and the wall of the room.
Any dust originating from construction work has to be kept off the installation (by covering).
For a more simple room planning the complete installation design is shown in the following.
Installation design prolog factory

Commissioning
Dimension drawing
3.3 Commissioning
Commissioning of the system can ensue only, if once all of the stations are connected to their final position.
The system possesses several components, which require connection before start-up. This process is
described in the following chapters.
3.3.1 Pneumatic commissioning

The mechanic set-up must be completed. In the beginning, the station is to be connected to the pneumatic
system in the room. The maintenance unit for the system is placed at one of the feet of the basic frame. The
quick coupling plug has a nominal size of 5 mm. In case the existing air supply system is equipped with 7.9
mm nominal size, it is possible to exchange the quick coupling plug of the maintenance unit with a larger
one (adapter 1/8 on 1/4 required).
Once this has ensued, the station can be supplied with 6 bar and the pneumatic commissioning is
concluded.

Commissioning
3.3.2 Electric commissioning

At this point, the system requires to be supplied with electric voltage
The cable included in the delivery has a standard plug for 230V/400V with protective covering, which is to
be plugged into a sufficiently secured socket. Distribution boards are included in the delivery, for the
connection of other components as well. In case an extension is required for the cable of the distribution
board, it is to be executed only by a trained expert. For the operators, the socket is to be secured.
To avoid problems during the operational process, individual protection (16A-230V / 40A-400V) of the
installation is recommended.
3.3.3 Connecting communication cables

The PRO-LOG Factory covers all state of the art industrial communication levels and control technologies.
The control levels are:
 Factory level: Order Entry
 Plant level: SCADA
 Device level: PLC, RC
The communication systems are:

 Ethernet (LAN/WLAN) for communication between PLC and PC (see also following graphic)
 RFID for communication between external I/O parts and PLC (see also following graphic)
 Profibus for communication between Siemens PLC and Turck IO extension

Commissioning
The communication inside the system takes place via Ethernet and Profibus DP. All connections are
pluggable, the exception is the cable from the Drive unit, the cable is fixed in the drive unit and not
pluggable.
Ethernet communication cables

Commissioning
Position Station Ethernet address
1 MES PC 192.168.10.50
2 WinCC 192.168.10.51
3 Triple stack magazine station 192.168.10.1
4 LAN-switch
5 WLan router 192.168.101.2
6 Testing station with color sensor 192.168.10.2
7 Processing station 192.168.10.3
8 Pick and place station 192.168.10.4
9 Fluid muscle station 192.168.10.5
10 Storing station 192.168.10.6
11 Separating station 192.168.10.7
12 Sorting station 192.168.10.8
13 Commissioning station 192.168.10.20
14 Drive Unit CR750 roboter 192.168.10.99
15 Robotino 1 192.168.10.101
16 Robotino 2 192.168.10.102

Commissioning
Profibus communication cables
Position Station Profibus DP address
1 Turk CPU commissioning station DP # 3
2 PLC commissioning station DP # 2
3 Drive unit roboter DP # 10
4 Turk connecting unit log area DP # 5

Commissioning
RFID communication cables
Position Station Name
1 RFID sensor robot 1C1
2 RFID Card 1 for RFID sensor robot and slide 1 1K2
3 RFID Card 2 for RFID sensor slide 2 and slide 3 1K3
4 RFID sensor slide 1 1C2

4 Operation
The chapter Operation describes the control units required for the operation, as well as start-up and close-
down of the system.
4.1 General operation notes

The stations require some rules of operation which should be observed. If they are not complied, faults in
the processes are possible. Dangers for the physical health also cannot be excluded.
It is recommended to observe the following rules strictly.
4.1.1 Behaviour rules

 During the operation of the stations it is forbidden to grip in by hand.
 With larger audience a mechanical protection of the stations is necessary.
 Removing any cable under tension is forbidden.
 Water has to be kept away from the plant.
4.1.2 Operation rules

 The stations only may be used by introduced persons.
 The operation has to be carried out according to the operating instructions.
 A pushing the different switches/push buttons of all control units unchecked has to be stopped.
 No workpiece carriers may be taken by the system.
4.2 Process description

Orders are entered and started in MES4 software.
The commissioning station has to equip a pallet like defined in the order. It is possible to equip the pallet
with 1-4 different work pieces.
The commissioning station requests the necessary work pieces at the separating and testing station. The
separating station gets the work pieces from the Storing station and the testing station gets the work pieces
from the distribution station. There the work piece is checked for height and the colour – the colour must fit
to the respective order, otherwise the work piece is sorted out on the slide.
If the pallet is equipped, the robot takes the pallet and places it down at the outlay slide from the station.
Robotino 1 takes the pallet from the slide and moves it to the high bay racking for temporary storage. From
there robotino 2 moves the pallet to the respective outlay slide (Slide 1-3) of the system. The requirement
therefore is that the slides are not occupied – in case the slides are occupied, it is necessary to put out the
pallets by hand. The RFID sensors announce this in MES software, there the orders are deleted.

Operation
4.2.1 Material flow

The processes and the material flow in PRO-LOG Factory is an image of a real production and distributing
enterprise. There are buffers and magazines for the raw materials, and a storage for the single products.
According to the customer orders, the products are transported JIS (just in sequence) to the commissioning
robot. The pallets are stored in a high bay storage.
The mobile robots are equipped with a fork on a telescope arm and work as a fork lift to reach the upper
positions of the high-bay racking.
Position Material flow Station
1 Equipped pallets to outlay slide 1 Robotino 2
4 Equipped pallets to high bay storage Robotino 1
5 Equipped pallets from high bay rack to outlay slides Robotino 2
6 Equipped pallets from commissioning station Robotino 1
7 Work pieces from MPS-System MPS Stations
8 Sort out work pieces Sorting Station
9 Empty pallets from AS/RS to slide 4 AS/RS Station
10 Empty pallets Robotino 1
11 Work pieces from MPS-System to commissioning station MPS Stations

Operation
Position numbers Robotino / orientation of pallets
Position Position number robotino
1 High bay rack position 1
7 Commissioning station output slide position 7
8 Commissioning station input slide position 8
9 Log area input slide position 9 / Init position robotino 1
10 Log area output slide 3 position 10
13 Init position robotino 2
The blu dots are the work piece positions on the pallets. There you can see the orientation of the pallet.

Operation
4.3 Robotino information and operation
4.3.1 General
The example is written for robotino 1, the operation of robotino 2 is equal.
If there is no operation at the panel during start up the robotino, the display is going to stand by mode,
press the Return button to bring back the panel to operation.
If the charge of the accumulator is not more than 50% it is possible that the robotino doesn’t work exactly –
in this case or in case of a crash press any button to stop the robotino.
To guarantee constant 5V it is necessary to connect the gyroscope to the USB-Hub at the robotino.
For further information’s to the robotino see also
http://www.festo-didactic.com/int-en/services/robotino/?fbid=aW50LmVuLjU1Ny4xNy4zNC4xMTY4
http://wiki.openrobotino.org/index.php?title=Main_Page
http://openrobotino.org/

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

2. Robotino makes the reference move. After reference move the robot is in start position and is waiting
for orders.
4.3.3 Switch off the robotino

To switch off the robotino press the power button for more than 3 sec. – The power supply light expires.

Operation
4.4 Program start

For both robotinos follow the informations on the display-screen
 If the light is not active, press enter
 Press enter, you will be in the main menu
 With the buttons, you have to go in the menu “programs”
 Here, you will see one of the both programs :
ProLog_V3.3_R1 / R1 is the robotino with the start-position 9
ProLog_V3.3_R2 / R2 is the robotino with the start-position 13.
 Position the robotino left-handed to the right position

 Start the program with enter

Operation
4.5 Robotino Startup

Step 1: Turn On the Robotino.
Step 2: Open the web interface (Preferably in Chrome or in latest version of Firefox )
Note: The default IP address is 192.168.10.101 for Robotino 1 and 192.168.10.102 for Robotino 2.

Operation
Step 3: Go to “Program”, select the appropriate program (Prolog_v3.3_R1.rvw2 for Robotino 1 and
Prolog_v3.3_R2.rvw2 for Robotino 2) and click on “Run” to start it.

Operation
4.5.1 Project upload

 Save the RobotinoView project.
 Close the RobotinoView.
 Open the webpage of the Robotino and go to “Program” page.
 Click on upload and select the project from your PC to be uploaded.

Operation
4.5.2 Sequence to collect one Palette

1. Wait for a job and save this job.
2. Save the right parameters: save the source and target-position for the Robotino and the fork. Calculate
the approach positions.
3. If the Robotino is already in the source-position: The fork drives to the lower fork position of the source
positon.
4. If the Robotino is not already in the source-position then its drives to this position: The Robotino leaves
the dock. It drives to the source approach position and finds the metallic line (with inductive sensor and
odometry). After that it adjusts the fork to the lower position of the source. Follows the line and finds
the black tape (with optical sensor).
5. Save the right parameters: save the right coordinates in the Odometry (if there is reference point at the
actual source)
6. The fork drives to the upper position of the source position. That means the Robotino takes the palette
at the source.
7. The Robotino leaves the dock.
8. The Robotino drives to the target approach position and finds the metallic line (with inductive sensor
and odometry). After that it adjusts the fork to the upper position of the target. Follows the line and
finds the black tape (with optical sensor).
9. Save the right parameters: save the right coordinates in the Odometry (if there is reference point at the
actual target)
10. The fork drives to the lower position. That means the Robotino gives the palette to the target.
11. If the Robotino is not in the storage warehouse (position-number between 1 and 6) then the sequence is
finished.
12. If the Robotino is in the storage warehouse (position-number between 1 and 6) then the Robotino must
drive to the start-position: The Robotino leaves the dock. It drives to the start approach position and
finds the metallic line (with inductive sensor and odometry). After that it adjusts the fork to the lower
position of the start. Follows the line and finds the black tape (with optical sensor).

Operation
Check the Robotino variable in the right column and set it accordingly:
set the uiRobotinoNo to 1 for Robotino 1 and two for Robotino 2

Operation
Click on any sub program to get a list of directories on the right side of the program window
Double click on UPD connection PLC control.

This opens a new window with the UDP connection settings. The IP address should be the same as the main
plc. The ports are different for the two robotinos:

Operation
Enter port 9180 for robotino 1: Enter port 9181 for robotino 2:

Operation
Close the UPD connection control window and click on Upload project in the menu robotino

Operation
4.6 Robotino-Pro-Log
Subprograms
Name Description
CalculateApproachPositions Calculate the approach positions
CalculateStartApproach Calculate the approach position for start position
DataExchange Dataexchange with the PLC via UDP
Drive Drive to the Target-position defined with pDriveSetpoint
DriveToSafePosition Drive to an intermediate safe position
FindLine Allign to the metal tape and set the xLineFound global variable
FindStop Search the black tape before the docking-position and set the xStopFound global variable
FinishJob Send job finished to the PLC
GetSourceAndTargetPos Get source and Target positions according to the job
GetStartPos Get start position according the start position number of the Robotino
Init Initialize several global variables for positions, Fork positions and UDP communication.
LeaveDock Leave the docking-position.
MoveBackALittle Robotino moves back ~1mm (Not used)
MoveForkDown Move Fork down (for referencing)
MoveForkUpSlowly Move Fork up slowly (for referencing)
MoveRight The Robotino moves to the right ~30cm (only if the source position number is 12)
PositioningFork The Fork drives to the position defined with the global variable iForkSetpoint.
RefernceFork Reference the Fork (set the actual fork position to 0)
SetDriveToSource Change pDriveSetpoint to Source position
SetDriveToStart Change pDriveSetpoint to Start position of the Robotino
SetDriveToTarget Change pDriveSetpoint to Target position
SetForkToLowerSource Change iForkSetpoint to the lower position of the Source
SetForkToLowerStart Change iForkSetpoint to the lower position of the Robotino's Start position
SetForkToLowerTarget Change iForkSetpoint to the lower position of the Target
SetForkToUpperSource Change iForkSetpoint to the upper position of the Source
SetForkToUpperTarget Change iForkSetpoint to the upper position of the Target
SetOdo Set Odometry to the pToRefOdo
SetSourceAsCurrent Set Current position number to the Source position number
SetStartAsCurrent Set Current position number to the Start position number of the Robotino
SetTargetAsCurrent Set Current position number to the Target position number
Start Send Robotino ready to the PLC
StartJob Send job started to the PLC
Test Prepared for manual tests after the Fork is referenced
WaitForJob Wait for job from the PLC

Operation
The Main Programm has several Parts, you can see that in the next schema:

Operation

Operation

Operation

Operation

Operation
4.6.1 Init Subprogram

In the init subprogram the user can set the parameters of the Robotino.
Variable name Description
uiRobotinoNo The Robotino's number (1: Robotino1, 2: Robotino2)
uiStartForRob1 Start postions for Robotino1
uiStartForRob2 Start postions for Robotino2
uiOffsetFront Position approaching distance X
uiOffsetRight Position approaching distance Y
And the user also able to change each Robotino positions, lower fork positions, upper fork positions.
4.6.2 Explanation
Initialization
 Wait the connection.
 Initialize the fork. (fork is down)
 Save the target position.
 Find the metallic line. (only with inductive sensors)
 Save the orientation.
 Find the black band.
 Save the coordinate of the start-position.

Operation
4.6.3 Sequence to collect one Palette

1. Wait for a job and save this job.
2. Save the right parameters: save the target-position for the Robotino and the fork.
3. If the Robotino is already in the source-position:
The fork drives to the position fork_posN_1. (N=number of the source)
4. If the Robotino is not already in the source-position then its drives to this position:
The Robotino leaves the dock.
In the same time, the Robotino drives to the target-position and do the following sequence:
1 Initialize the fork.
2 Save the origin of the fork.
3 The fork drives to the position fork_posN_1. (N=number of the source)
The Robotino finds the metallic line. (with inductive sensor and odometry)
The Robotino finds the black band. (with optical sensor)
5. Save the right parameters: save the right coordinates in the Odometry and save the next target-position
for the fork.
6. The fork drives to the position fork_posN_2. That means the Robotino takes the palette in the source.
7. The Robotino leaves the dock.
8. Save the right parameters: save the target-position for the Robotino and the fork.
9. The Robotino drives to the sink-position:
In the same time, the Robotino drives to the target-position and do the following sequence:
1 Initialize the fork.
2 Save the origin of the fork.
3 The fork drives to the position fork_posN_2. (N=Number of the sink)
The Robotino finds the metallic line. (with inductive sensor and odometry)
The Robotino finds the black band. (with optical sensor)
10. Save the right parameters: save the right coordinates in the Odometry and save the next target-position
for the fork.
11. The fork drives to the position fork_posN_1. That means the Robotino gives the palette in the sink.
12. If the Robotino is not in the storage warehouse (position-number between 1 and 6) then the sequence is
finished.
13. If the Robotino is in the storage warehouse (position-number between 1 and 6) then the Robotino must
drive to the start-position:
The Robotino leaves the dock.
Save the right parameters: save the target-position for the Robotino.
In the same time, the Robotino drives to the target-position and initialize the fork.
The Robotino finds the metallic line (with inductive sensor and odometry).
The Robotino finds the black band (with optical sensor).
Save the coordinate of the start-position.

Operation
4.6.4 Global Variables
Type Name Description
unsigned int uiBattery Value of the Batteries in Volt.
array aiLowerForkPos Array for lower fork positions
array aiUpperForkPos Array for upper fork positions
array apPositions Array for Robotino positions
array axSetOdo Array for mark positions where the robotino can set the odometry
int iCurrentPhi Current Phi value of the Robotino
int iCurrentPos Current position number of the Robotino
int iCurrentX Current X position of the Robotino
int iCurrentY Current Y position of the Robotino
int iForkSetpoint Setpoint for Fork positioning
int iSourceLowerForkPos Lower Source position of the Fork for the current job
int iSourceUpperForkPos Upper Source position of the Fork for the current job
int iStartLowerForkPos Lower position of the Fork for the start position
int iTargetLowerForkPos Lower Target position of the Fork for the current job
int iTargetUpperForkPos Upper Target position of the Fork for the current job
pose pDriveSetpoint Setpoint for Robotino positioning
pose pSource Source Robotino position for the current job
pose pSourceApproach Approach position of Source for the current job
pose pStart Start position of Robotino
pose pStartApproach Approach position for the Robotino start position
pose pTarget Target Robotino position for the current job
pose pTargetApproach Approach position of Target for the current job
pose pToRefOdo Postion value to reference the odometry
unsigned int uiCurrentPos Indicates the last position that the robotino has reached

Operation
Type Name Description
unsigned int uiIntegrator The integrator value in the PositioningFork subprogram
unsigned int uiOffsetFront Position approaching distance X
unsigned int uiOffsetRight Position approaching distance Y
unsigned int uiRobotinoNo The Robotino's number (1: Robotino1, 2: Robotino2)
unsigned int uiStartForRob1 Start postions for Robotino1
unsigned int uiStartForRob2 Start postions for Robotino2
unsigned int uiStartPos Start position number of Robotino
unsigned int uiToOdo Position number after setting Odometry
bool xDockLeft Robotino left the dock (timer delay)
bool xForkAtLowerPos Fork is reached the lower inductive sensor (limit switch)
bool xForkPosReached Fork is reached the setpoint value
bool xLineFound Robotino has aligned with the metallic tape
bool xPosReached Robotino Reached the setpoint position
bool xSetOdoAtSource Whether Odometry should be set at Source or not
bool xSetOdoAtTarget Whether Odometry should be set at Target or not
bool xStopFound Robotino has found the black tape
unsigned int uiJobState State of the Job (to UDP)
bool xReady Robotino is ready for get a job (to UDP)
bool xJobStart Start job signal (from UDP)
unsigned int uiJobSource Source position number (to UDP)
unsigned int uiJobTarget Target position number (to UDP)
4.7 Data Exchange Variables
Name Description
CurrentPos Number of the current position (between 1 and 13).
job_running True, when the Robotino works about an order.

False, when the Robotino is waiting an order.
job_sink Sink-number of the next order transmitted via UDP to Robotino View.
job_source Source-number of the next order transmitted via UDP to Robotino View.
X Coordinate of the Robotino (given by the odometrie) in the table-coordinates´ system.

Y
Phi
These variables are present in the both programs.

Operation
4.8 Log area information and operation

4.8.1 General
Position Function Position Function
1 High bay rack 6 Robotino 2
2 Robotino 1 7 Output slide 1 (order 1)
3 Slide from commissioning station to log area 8 Output slide 2 (order 2)
4 Slide from Log area to commissioning station 9 Output slide 3 (order3)
5 Turk controller board 10 Input slide 1 (empty pallets)
There is no operation system for the log area. The control for the log area is done from the controller on the
turk board. The board is supplied with 24 V from a extern power supply unit, be sure that the power supply
unit is switched on.
The lamps at the slides announce that a order is ready and the pallet is on the slide.

Operation
The silver help lines on the table are for the Robotino, with a inductive sensor the Robotino follows the right
edge of the line. The black markers are the stopping point for the Robotino, a optical sensor recognize the
marker. The help lines are available at the slides and at the high bay rack.
Position Function
1 Silver help line (aluminium tape)
2 The robotino orientates at the right edge of the help line
3 Direction of robotino to handing over a pallet to a slide
4 Marker to stop the robotino in the right position

Operation
High bay rack
Position Function
4.8.2 Start up log area

 Remove all parts from the outlay slides
 Remove all parts from high bay racking
 Fill up the Input slide with empty pallets

Operation
4.9 Start up MPS stations

The operation of the stations is described in the stations manual – a short cut for operation to start up the
system should be helpful. All stations have the same procedure.
4.9.1 Requirements
The reset process is the same for each MPS station. Execute the reset process at each station. The reset
process is also to be executed after STOP- or EMERGENCY-STOP activation.
1. Fill up all magazines
2. Clear all working positions
4.9.2 Reset process of MPS-stations

The MPS-stations can be started with the reset process, as following.

Operation
4.10 Start up commissioning station

The operation of the station is described in the stations manual – a short cut for operation to start up the
system should be helpful.
4.10.1 Requirements
Execute the reset process at the robot station. The reset process is also to be executed after STOP- or
EMERGENCY-STOP activation.
1. Clear all working positions, slides, the high bay rack at the log area and the pallet reception at
commissioning station.
2. Switch on power and air supply
3. Key switch on Drive Unit to Auto/EXT
Switch Teach Box to disable
Switch on Drive Unit from robot
4.10.2 Reset process robot station

Operation
4.11 Default mode

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

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

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

Operation
4.12 MES Mode

The MES mode is for automatic mode of the complete system. Operation and order handling is done by the
MES4 Software.
1. Turn Key switch at all stations to MES mode (vertical – Auto)

2. Fill up magazine at triple stack magazines (MPS)
3. Prepare storage (MPS) equal the settings in MES
4. Remove all workpieces from storage
5. Remove all workpieces from working positions
6. Remove all workpieces from conveyor positions
7. Remove all workpieces from buffer at Log Area
8. Place empty pallet to input slide at log area
9. Start all stations with START button
10. Operation is done by MES Software (See chapter process description)
11. Announcement is done in WinCC

5 WinCC
5.1 System information
The system is extended with a communication layer for using a SCADA system (Supervision, Control And
Data Acquisition) like WinCC, for this system it is called "Level 2". For data exchange between SCADA
system WinCC and the PLCs an Ethernet network is used.
It is possible to configure the facility; single MPS-stations can be removed or relocated. If this is done,
WinCC can conform to the real system.
5.1.1 Start-up WINCC

Before activating WinCC you have to make sure all programs have been downloaded to each PLC and all
system cable connections are made:
 DC24V power supply
 6bar system pressure
 I/O communication cables according to operation manual
Ethernet cables connecting each PLC and computer

Ethernet cables are connected with the Ethernet switch
Ethernet switch is switched on
Profibus cables connecting PLC commissioning with Turk board
System requirements:
 Windows XP with SP2/Vista, English or German Version with Internet Explorer V6.0
 Ethernet-card installed to the computer
 WinCC V7.0 with SP1 with WinCC-Application
Notice:
Please make sure that all software and hardware has been installed in this order!

WinCC
5.2 Use Runtime Application

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

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

WinCC
Alarm in I/O´s window
Position Function
1 Announcement of alarm at this station
2 Announcement of alarm somewhere in the system
3 Button to change to alarm window
Alarm class description

 ERROR_L0 / fatal error, station doesn’t work anymore, solve problem, quit Error and reference move
necessary
 ERROR_L1 / still working and stops at the cycle end, quit error and push START button
 ERROR_L2 / warning, station is still working, if necessary quit error

WinCC
Alarm window warning
Position Function
1 Detailed alarm announcement / background grey for warning
2 Acknowledge and delete all alarms
3 Cancel alarm window without acknowledge the alarm

WinCC
Alarm window / error
Position Function
1 Detailed alarm announcement / background red for error
2 Acknowledge and delete all alarms
3 Cancel alarm window without acknowledge the alarm

WinCC
Shut down menu
Position Function
Choose function
- Deactivate WinCC runtime and change to windows / WinCC is still active
1 - Close project and shutdown WinCC to change to windows
- Restart computer
- Shutdown computer
2 Acknowledge function from shut down menu
3 Cancel shut down menu and change back to WinCC runtime

WinCC
Configuration window
Position Function
1 Fault is announced (only in flash animation) / marked with the red frame
2 Description of fault
3 Confirm fault

6 Process description
6.1 Triple stack magazine
6.1.1 Standalone mode of Triple stack magazine
In standalone mode the Triple stack magazine distributes different types of workpieces one after another.
First red, then black, silver, red again, and so on. If a magazine is empty, it automatically jumps to the next
type of workpiece.
Sequence of distribution
 First we select the color. For example if the station distributes a red previously, then it changes to black
[spAuto].
 According to the color of the workpiece to distributed, different cylinders will be extended
[spExtRed / spExtBlack / spExtSilver]. If the magazine is empty, the station will be on Idle state [stIdle].
 When the workpiece arrives at the end of conveyor, the cylinder will be retracted [spRetract].
 Simultaneously the conveyor will stop 1 sec after the workpiece passes the sensor at the end of
conveyor [spStopConv].
 Then the station will be on Idle state [spIdle].
spIdle
Station on Idle state
Station in standalone mode,

and next station is free
spAuto
Change color to the
next.
Red, and magazine 1 Black, and magazine 2 Silver, and magazine 3

Else
is not empty is not empty is not empty
spExtRed spExtBlack spExtSilver spMagEmpty

Extend cylinder at Extend cylinder at Extend cylinder at Empty: Jump back to
magazine 1 magazine 2 magazine 3 spIdle
Workpiece at
conveyor end (-3B1)
spRetract spWait1s
Retract the cylinder at
Empty: Wait 1 sec
the magazine
Cylinder is retracted 1 sec later
spStopConv
Stop the conveyor
motor

Process description
6.1.2 MES mode of Triple stack magazine

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

Process description
spIdle MES_CyclicRequestForOrder
Cylcically request for task in
Station on Idle state every second.
Station in MES mode, task received, and

next station is free
spMES
Registrate the color
Red, and magazine 1 Black, and magazine 2 Silver, and magazine 3

Else
is not empty is not empty is not empty
spRedStart spBlackStart spSilverStart spMagEmpty

Entry: Send "Task Entry: Send "Task Entry: Send "Task Empty: Jump back to
Started" (M100.10) Started" (M100.10) Started" (M100.10) spIdle
Answer received Answer received Answer received
spExtRed spExtBlack spExtSilver

Extend cylinder at Extend cylinder at Extend cylinder at
magazine 1 magazine 2 magazine 3
Workpiece at
conveyor end (-3B1)
spSendFinished
Entry: Send "Task
Finished" (M101.1)
Answer received
spRetract spWait1s
Retract the cylinder at
Empty: Wait 1 sec
the magazine
Cylinder is retracted 1 sec later
spStopConv
Stop the conveyor
motor
spWaitForVali...
Empty: Wait for next
station (validation)
Next station finished

Process description
6.2 Testing Station

6.2.1 Standalone mode of Testing Station
In standalone mode the Testing Station checks only the orientation of the workpieces. If the workpiece is
hole side up, then the station transports it to the next station. If the workpiece is hole side down, then the
station will transport it to the waste slide.
Sequence of validation
 If a workpiece arrives, the station switches the conveyor belt motor on, and waits for 1 sec
[spConveyorOn]
 Then the station checks the orientation of the workpiece with a laser sensor [spCheck].
 If the orientation of the workpiece is not ok:
The station extends the gate to the waste slide [spExtendGate].
The stopper cylinder will be retracted [spRetrStopper].
Then the station waits until the workpiece arrives on the waste slide [spWait3B1].
 If the orientation of the workpiece is ok:
The station waits for the next station [spWaitNext].
The station waits until the next station starts working [spWaitNotNext].
Then waits for 1 sec more [spWait1s].
 The gate is retracted (if it was extended), the stopper is extended, and the conveyor motor is stopped
[spStop].
 After the gate arrives to initial state, the station will be on Idle state [spIdle].

Process description
spIdle
Station in Idle state
Station in standalone mode, and

workpiece arrived
spConveyorOn
Switch on conveyor
belt motor
1 sec later
spCheck
Check orientation
Orientation is ok Orientation is not ok
spWaitNext spExtendGate
Empty: Wait until next Extend gate to the Save the workpiece type
station is free waste slide
Next station is free Gate extended
spRetrStopper
Retract the stopper
cylinder
Orientation was ok Orientation was not ok
spWaitNotNext spWait3B1
Wait until next station Empty: Wait until work
starts working piece on slide
Next station is free workpiece on slide
spWait1s
Empty: Wait 1 sec
After 1 sec
spStop
Retr. Gate, ext. Stop-
per, stop conveyor
Gate in intial state

Process description
6.2.2 MES mode of Testing Station

In MES mode the Testing Station asks for the color from the MES server. If the workpiece is hole side down,
or the color does not match, the station will transport it to the waste slide. If the color and orientation are
good, the station transports the workpiece to the next station.
Sequence of validation
 If a workpiece arrives, the station switch the conveyor belt motor on, and waits for 1 sec [spConveyorOn]
 Then asks for task. It sends the “Ask for a Task” message (M100.1) [spAskForOrder].
 If the station gets a task, it sends back a “Task Started” message (M100.10) [spSendStarted].
 Then the station checks the workpiece with the color sensor, and laser sensor [spCheck].
 If the color or the orientation of the workpiece is not ok, or there is no task:
The station extends the gate to the waste slide [spExtendGate].
Then the station waits until the workpiece arrives on the waste slide [spWait3B1].
Simultaneously the station sends “Task Finished with Error” message (M101.1 with error) [spSendError]
 If the color and the orientation of the workpiece are ok:
The station waits for the next station [spWaitNext].
The station waits until the next station starts working [spWaitNotNext].
Then waits for 1 sec more [spWait1s].
Then the station sends “Task Finished” message (M101.1) [spSendFinished].
 The gate is retracted (if it was extended), the stopper is extended, and the conveyor motor is stopped
[spStop].
 After the gate arrives to initial state, the station will be on Idle state [spIdle].

Process description
spIdle
Station in MES mode, and workpiece

arrives
spConveyorOn
Switch conveyor belt
motor on
1 sec later
spAskForOrder
Entry: Send "Ask for a
Task" (M100.1)
Answer received
spSendStarted
Entry: Send "Task
Started" (M100.10)
Answer received
spCheck
Check color and
orientation
Orientation and color Orientation or color is

are ok not ok, or no task
spWaitNext spExtendGate
Empty: Wait until next Extend gate to the Registrate the workpiece type
station is free waste slide
Next station is free Gate extended
spRetrStopper
Retract the stopper
cylinder
Orientation and color Orientation or color

were ok was not ok , or no task
spWaitNotNext spWait3B1 spSendError

Wait until next station Empty: Wait until Entry: Send "Task
starts working workpiece on slide Finished with error" (M101.1 with error)
Next station is free workpiece on slide Answer received
spWait1s
Empty: Wait 1 sec
After 1 sec
spSendFinished
Entry: Send "Task
Finished" (M101.1)
Answer received
spStop
per, stop conveyor

Process description
6.3 Processing Station

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

Process description
2 1
spIdle
Station on Idle state Hole side up Hole side down
spFix
Workpiece arrives
Fix the workpiece
spWait1s
Empty: Wait 1 sec After 1 sec
spDrillDown
1 sec later
Switch the drill on, and
spRotate1_1 drill unit moves down
Give start signal for Drill unit is in bottom

rotation of table position
spDrillUp
Table is not in position
Drill unit moves up
spRotate2_1
Reset start signal for Drill unit is in top
rotation of table position
spDrillOff
Table is in position
Switch the drill motor
spTesting off
Testing unit moves

down
spRelease
After 1 sec
Release the workpiece
spCheck
Empty: Check the hole
spRotate1_3
Give start signal for
Hole side up Hole side down
rotation of table
spOk spNotOk
Set workpiece type to Set workpiece type to
ok not ok spRotate2_3
Reset start signal for
rotation of table
spTestingUp
Testing unit moves up
spWaitNext
Empty: Wait until next
After 1 sec
station is free
spRotate1_2
Next station is free
Give start signal for
rotation of table spEject
Eject workpiece to
next station
spRotate2_2
After 1 sec
Reset start signal for
rotation of table spStop
Retract the eject
solenoid
2 1

Process description
6.4 Pick & Place Station

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

Process description
2 1
spIdle
spExtend
Extend the horizontal
cylinder
Workpiece arrives
Horizontal cylinder is
spSepExt extended
spDown2
Extend the separator
Move down with the
instrument
Not in upper position

spConvOn
Switch the conveyor spDrop
motor on
Switch the vacuum off
Workpiece passes the sensor before the (drop the instrument)
separator
No vacuum
spWaits1s
spUp2
Empty: Wait 1 sec
Move up
1 sec later
In upper position
spConvOff
Switch the conveyor
motor off spRetract spWaitNext
Retract the horizontal Empty: Wait for next
cylinder station
spDown
Move down to
instrument spSepRetr
Vertical cylinder is not Switch conveyor on,
in upper position retract separator
spVacuumOn
Switch vacuum on Workpiece at conveyor end
spWaits1s_2
Skipping the vacuum error is
Vacuum sensor is on Empty: Wait 1 sec
active (xSkipVacError)
spWait2s
1 sec later
Empty: Wait 2 sec
spConvOff2
Switch the conveyor
2 sec later
motor off
spUp
Move up with the
instrument
In upper position
2 1

Process description
6.5 Fluidic Muscle Press Station

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

Process description
spIdle
Workpiece arrives
spWaits2s
Empty: Wait 2 sec
2 sec later
spClose
Close the gripper
1 sec later
spRotateProc
Rotate to the
processing position
Rotary drive at
processing position
spPressDown
Pressing unit moves
down
Pressure reached
spPressUp
Pressing unit moves
up
2 sec later
spRotateDown
Rotate to the
downstream station
Rotary drive at downstream

station position
spWaitDown
Wait for next station
spOpen
Open the gripper
1 sec later
spMoveUp
Retract the horizontal
cylinder
Liner drive at upstream

position
spRotateUp
Rotate to upstream
position
Rotary drive at upstream

station position

Process description
6.6 Storing Station

6.6.1 Standalone mode of Storing Station
In standalone mode there are two tasks (insertion, removal). The station switches between each of the tasks
one after the other.
The first task is inserting the incoming workpiece into the storage. Each colors are sorted on different
shelves (from the top: red, black, silver). The station searches from the right side for an empty tray. If there
is no free place for the workpiece, it will be transported to the next station.
The second task is the removal. If the next station is free, the Storing Station searches for the color, which
occurs the most, and transports it from the storage to the next station. The station searches from the right
side for a workpiece.
 If a workpiece arrives the station moves above the workpiece [spMoveAboveIn_c1].
 It clears the number of failed color checks [spCheckNum0_c1].
(It should count the number of fails of color checks, because if it failed three times in a row, there is a
problem with the color sensor, and the station has to go to error state.)
 Then the station extends the horizontal cylinder [spExtend_c1].
 Then it checks the color [spCheckColor_c1].
 If the color check fails:
Retracts the horizontal cylinder, and increases the number of failed color checks [spRetract_c1].
Then checks whether there is still a workpiece or not [spCheckWp_c1].
If there is still a workpiece jumps back before color check [spExtend_c1], else the station jumps back to
Idle state [spIdle].
 Then the station search for an empty tray for workpiece [spSearchIPlace]. If there is no free place, the
workpiece will be transported to the next station.
 Moves down to the workpiece [spMoveIn_c1].
 Closes the gripper [spClose_c1].
 Moves up with the workpiece [spMoveAboveIn_c2].
 Retracts the horizontal cylinder [spRetract_c2].
 Moves above the empty tray, or above the input of the next station [spMoveAboPlace_c1].
 If the workpiece was transported to the next station :
Retracts Waits until the next station is free [spWaitNext_c1].
 Extends the horizontal cylinder [spExtend_c2].
 Moves to the tray or to the input of the next station [spMovePlace_c1].
 Opens the gripper [spOpen_c1].
 If the workpiece was transported to a tray :
Registrates the insertion [spRegIns_c1].
 Retracts the horizontal cylinder [spRetract_c3].

Process description
1 2
spIdle
spRetract_c2
Retract horizointal
cylinder
Station in standalone mode, insertion is
selected, and workpiece arrives
Horizontal cylinder
spMoveAb.In_c1 retracted
Move above the up- spMoveAb.Pl._c1

stream station pos.
Move above the place
Motion finished
Motion finished
spCheckNum0_c1
Reset the number of Insertion into
the storage not Else
color checks
to the next
station spWaitNext_c1
Wait for next station
spExtend_c1
cylinder
Horizontal cylinder
extended spExtend_c2
spCheckColor_c1 Extend the horizontal
cylinder
Check and registrate
the type of the wp. Horizontal cylinder
extended
1 sec later
spMovePlace_c1
Workpice color was
Else Move to the place
detected
spSearchIPlace If there is no free spRetract_c1

place select the Motion finished
Search free place for Retract horizointal In entry action increase the
next station for
insertion cylinder number of color checks spOpen_c1
insertion.
Horizontal cylinder
Open the gripper
retracted
spMoveIn_c1 spCheckWp_c1
1 sec later
Move to the upstream Empty: Check if there
station position is a workpice or not If inserted into the
Else
storage
Motion finished
There is no workpiece There is a spRegIns_c1
spClose_c1 (it was removed) workpiece Registrate the
insertion
Close the gripper
1 sec later
spRetract_c3
spMoveAb.In_c2 Retract horizointal
Move above the up- cylinder
stream station pos. Horizontal cylinder
retracted
Motion finished
1 2

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

Process description
1 2
spIdle
spRegRem_d1
Registrate the
removal
Station in standalone mode, removal is
selected, and the storage is not empty
spSelColor_d1
Select color (which spRetract_d1
occurs the most) Retract the horizontal
cylinder
Horizontal cylinder
spSearchRPlace retracted
Search for the selec- spMo.Ab.Out_d1

ted color in storage
Move above
downstream station
If there is a wp. with

Else Motion finished
the selected color
spMovePlace_d1 spExtend_d2
Move to the place
cylinder
Horizontal cylinder
Motion finished
extended
spExtend_d1 spMo.OutLin_d1
Extend the horizontal Move to downstream
cylinder station (only linear)
Horizontal cylinder
Motion finished
extended
spClose_d1 spOpen_d1
Close the gripper Open the gripper
1 sec later 1 sec later
spMoveAb.Pl._d1 spRetract_d2
cylinder
Horizontal cylinder
Motion finished
retracted
1 2

Process description
6.6.2 MES mode of Storing Station

In MES mode there are two tasks (insertion, removal). The station switches between each of the tasks one
after the other.
The first task is inserting the incoming workpiece into the storage. After the station detects the color, it asks
for a task from MES server. If there is an order for the specific color of the workpiece, it will serve it. If there
is no order for the color, the station asks the MES server for an empty tray, and inserts the workpiece into
this tray. If there is no free place, the workpiece will be transported to the next station.
The second task is the removal. If the next station is free, the Storing Station asks the MES server for an
order. If there is an order, the station transports it from the storage to the next station.
 If a workpiece arrives the station moves above the workpiece [spMoveAboveIn_a1].
 It clears the number of failed color checks [spCheckNum0_a1].
(It should count the number of fails of color checks, because if it failed three times in a row, there is a
problem with the color sensor, and the station has to go to error state.)
 Then the station extends the horizontal cylinder [spExtend_a1].
 Then it checks the color [spCheckColor_a1].
 If the color check fails:
Retracts the horizontal cylinder, and increases the number of failed color checks [spRetract_a1].
Then checks whether there is still a workpiece or not [spCheckWp_a1].
If there is still a workpiece jumps back before color check [spExtend_a1], else the station jumps back to
Idle state [spIdle].
 Then the station asks for the next order from the MES (M100.1) [spAskForOrder_a1).
 If there is an order for the station:
It asks for the parameters of the order (M100.21) [spAskForParameters_a1].
Then registrates the color from the answer [spSaveColor_a1].
If the color of workpiece and order match:
The stations ends “Task Started” message (M100.10) [spSendStarted_a1]
Moves to the workpiece [spMoveIn_a1].
Closes the gripper [spClose_a1].
Lifts up the workpiece [spMoveAboveIn_a2].
Retracts the horizontal cylinder [spRetract_a2].
Moves above the input of next station [spMoveAboveOut_a1].
Waits until the next station is free [spWaitNext_a1].
Extends the horizontal cylinder [spExtend_a2].
Moves to the input of the next station (use only the linear axes) [spMove.OutLin_a1].
Opens the gripper, drops the workpiece [spOpen_a1].
Retracts the horizontal cylinder [spRetract_a3].
Send a “Task finished” message (M101.1) [spSendFinished_a1].
Then the station jumps back to Idle state [spIdle].
 Then the station asks for an empty tray for the workpiece from MES [spSearchMESIPlace].
 Then the station calculates the row and column number from the tray number [spCalcColRowI_a1]. If
there is no empty tray, the workpiece will be transported to the next station.

Process description
 Moves down to the workpiece [spMoveIn_a2].

 Closes the gripper [spClose_a2].
 Moves up with the workpiece [spMoveAboveIn_a3].
 Retracts the horizontal cylinder [spRetract_a4].
 Moves above the empty tray, or above the input of the next station [spMoveAboPlace_a1].
 If the workpiece was transported to the next station :
Retracts Waits until the next station is free [spWaitNext_a4].
 Extends the horizontal cylinder [spExtend_a3].
 Moves to the tray or to the input of the next station [spMovePlace_a1].
 Opens the gripper [spOpen_a2].
 If the workpiece was transported to a tray :
Registrates the insertion [spRegIns_c1].
And simultaneously registrates the insertion in MES(M100.31) [spRegInsMES].
 Retracts the horizontal cylinder [spRetract_a5].

Process description
spIdle
Station in MES mode, insertion is selected,

and workpiece arrives
spMoveAb.In_a1
Move above the up-
stream station pos.
Motion finished
spCheckNum0_a1
Reset the number of
color checks
spExtend_a1
cylinder
Horizontal cylinder
extended
spCheckColor_a1
Check and registrate
the type of the wp.
1 sec later
Workpice color was

Else
detected
spRetract_a1
Retract horizointal In entry action increase the
cylinder number of color checks
Horizontal cylinder
retracted
spCheckWp_a1
Empty: Check if there
is a workpice or not
There is no workpiece There is a

spAskForOrder_a1 (it was removed) workpiece
Entry: Ask for an order

(M100.1)
Answer received
There is no task for the

Else
station
spAskForPara._a1
Entry: Ask for param.
(M100.21)
Answer received
spSaveColor_a1
Registrate color from
answer
Task and workpiece

Else
color do not match
spSearchMESIPla. spSendStarted_a1
Search free place for Entry: Send "Task
insertion Started" (M100.10)
Answer received Answer received
spCalcColRowI_a1 If there is no free spMoveIn_a1

place select the
Calculate the row and Move to the upstream
next station for
column number station position
insertion.
Motion finished
1 2 3 4

Process description
1 2 3 4
spMoveIn_a2 spClose_a1
Move to the upstream
Close the gripper
station position
Motion finished 1 sec later
spClose_a2 spMoveAb.In_a2
Move above the up-
Close the gripper
stream station pos.
1 sec later Motion finished
spMoveAb.In_a3 spRetract_a2
Move above the up- Retract horizointal
stream station pos. cylinder
Horizontal cylinder
Motion finished
retracted
spRetract_a4 spMov.Ab.Out_a1
Retract horizointal Move above the down-
cylinder stream station pos.
Horizontal cylinder
Motion finished
retracted
spMoveAb.Pl._a1 spWaitNext_a1
Move above the place Move above the place
Motion finished Next station is free
Insertion into spExtend_a2

the storage not Else
to the next Extend the horizontal
station spWaitNext_a2 cylinder
Horizontal cylinder
extended
spMov.OutLin_a1
Move to downstream
station (only linear)
spExtend_a3
Motion finished
cylinder spOpen_a1
Horizontal cylinder
Open the gripper
extended
spMovePlace_a1
1 sec later
Move to the place
spRetract_a3
Retract horizointal
Motion finished
cylinder
spOpen_a2 Horizontal cylinder

retracted
Open the gripper
spSendFinish._a1
Entry: Send "Task
1 sec later
Finished" (M101.1)
If inserted into the

Else Answer received
storage
spRegIns_a1 spRegInsMES
Registrate the Entry: Registrate the
insertion insertion in MES
spRetract_a5
Retract horizointal
cylinder
Horizontal cylinder
retracted

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

Process description
1 2
spIdle

spRegRem_d1 spRegRemMES
Station in MES mode, removal is selected, Entry: Registrate the
Reistrate the removal
and there is an order removal in MES
spAskForPara._b1
Answer received
Entry: Ask for
parameters (M100.21)
spRetract_b1
Answer received
spSea.MESRPl._b1 cylinder
Entry: Search for tray Horizontal cylinder

with MES retracted
spMo.Ab.Out_b1
Answer received
Move above
spSearchMESRPla. downstream station
Entry: Ask for place

Motion finished
from MES (M100.30)
spExtend_b2
Answer received
spCal.Co.Ro.R_b1 cylinder
Calculate the column Horizontal cylinder

and row from param. extended
spMo.OutLin_b1
If there is a wp. with Move to downstream
Else
the selected color station (only linear)
spSendStarted_b1
Motion finished
Entry: Send "Task
Started" (M100.10) spOpen_b1
Answer received Open the gripper
spMovePlace_b1
1 sec later
Move to the place
spRetract_b2
Motion finished
cylinder
spExtend_b1 Horizontal cylinder

Extend the horizontal retracted
cylinder spSendFinish._b1
Horizontal cylinder Entry: Send "Task
extended Finished" (M101.1)
spClose_b1
Answer received
Close the gripper
1 sec later
spMoveAb.Pl._b1
Motion finished
1 2

Process description
6.7 Separating Station

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

Process description
spIdle

arrives
spWait2s
Empty: Wait 2 sec
2 sec later
spConv1On
Switch the main
conveyor on
Workpiece at check
position
spWait1s
Empty: Wait 1 sec
1 sec later
spCheck
Check and reg. the
type of the workpiece
Workpiece is black or
Else
silver
spExtGate spNotOk
Extend the separator Save that the work- Registrate the workpiece type
and switch conv. 2 on piece was not good
Separator is not
retracted
spWaitNext
Wait until next station Wait for sorting or for
is free the robot buffer.
spRetrStop
Retract the stopper
Workpiece arrives at the

end of any conveyor
spWait2s_2
Empty: Wait 2 sec
2 sec later
spStop
per, stop conveyors

Process description
6.7.2 MES mode of Separating Station

In MES mode the Separating Station asks the server about the next order. If the coming workpiece has the
same color than the order, the station transports it to the Robot Station with the separator gate. If the color
of the workpiece is not correct, it will be transported to the Sorting Station.
Sequence of separation in MES mode

 After a workpiece arrives the station waits for 2 sec [spWait2s]. (It waits for the Storing Station.)
 Then switches the main conveyor motor on [spConv1On].
 After the workpiece arrives to check point it waits for 1 sec [spWait1s].
 Then the station asks for an order (M100.1) [spAskForOrder].
 If it gets a task, it sends a “Task Started” message (M100.10) [spSendStarted].
 Then it checks the color and material [spCheck].
 If the color, material of the workpiece and the order are same:
Extends the separator gate, switches the perpendicular conveyor on, and registrates that the workpiece
was good [spExtGate].
If the color, material of the workpiece and the order are different:
Registrates that the workpiece was not good [spNotOk].
 Then the station waits for the next station [spWaitNext].
 After the next station is free, the station retracts the stopper [spRetrStop].
 After the workpiece arrives at the end of either of conveyor, the station waits for 2 sec [spWait2s_2].
 2 sec later it retracts the separator, extracts the stopper and stops the conveyors [spStop].
 If the workpiece was good, the station inserts the workpiece into the buffer (M100.36) of the Robot
Station [spInsertFIFO].
 According to the type of the workpiece, the station sends a “Task Finished” message (M101.1) with or
without error [spSendFinished].
 After that the station will be on Idle state [spIdle].

Process description
2 1
spIdle
spWaitNext
Wait until next station Wait for sorting or for
is free the robot buffer.
arrives
spWait2s
spRetrStop
Empty: Wait 2 sec
Retract the stopper
2 sec later
Workpiece arrived to the
spConv1On end of either of conveyor
Switch the main spWait2s_2

conveyor on
Empty: Wait 2 sec
Workpiece at check
position
2 sec later
spWait1s
spStop
Empty: Wait 1 sec
per, stop conveyors
1 sec later
spAskForOrder
Entry: Send "Ask For a spInsertFIFO
Task" (M100.1)
Entry: Insert wp. In
If the workpiece was good
rob. FIFO (M100.36)
Answer received
Answer received
spSendStarted
Entry: Send "Task If there is a task for the spSendFinished If there was a task.
Started" (M100.10) station.
Entry: Send "Task Accorindg to the workpiece
Finished" (M101.1) type, with or without error.
Answer received
Answer received
spCheck
Check and reg. the
type of the workpiece
Workpiece is good Else
spExtGate spNotOk
Extend the separator Reg. that the work- Registrate the workpiece type
and switch conv. 2 on piece was not good
Separator is not
retracted
2 1

Process description
6.8 Sorting Station

6.8.1 Standalone mode of Sorting Station
In standalone mode the Sorting Station sorts out the different types of workpieces to different slides.
The Sorting Station does the same in MES mode.
Sequence of sorting
 If a workpiece arrives the station switches the conveyor motor on and waits for 2 sec [spConvOn].
 Then checks the color and the material with an inductive-, and an optical sensor.
 According to the material and color, the station extends a separator or not
[spExtRed / spExtBlack / spExtSilver].
 Then retracts the stopper [spRetrStoper].
 Waits for the falling edge of the sensor at the slides (-B4) [spWaitNotB4].
 Retracts the separator (if it was extended), and extends the stopper [spStop].
 If all separators are retracted, the station will be on Idle state [spIdle].
spIdle
Workpiece arrives
spConveyorOn
Switch the conveyor
motor on
Workpiece is red Workpiece is black Workpiece is silver
spExtRed spExtBlack spExtSilver

Extend the first Extend the second Do not extend any
separator separator separator
First separator is Second separator is

extended extended
spRetrStoper
Retract the stopper
The sensor at the slide

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

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

Process description
6.9 Robot Station and Robotinos

6.9.1 Standalone mode of Robot Station and Robotinos
In standalone mode the Robot Station and the Robotinos work only in a simple sequence (in an infinite
loop). The Robotino 1 moves an empty pallet from the input slide to the Robot Station. The Robot moves it
to the next pallet place, and then commissioned it with for workpieces. The Robot moves the commissioned
pallet to the output slide. The Robotino 1 transports it to the next position of the stock, and moves back to
the output slide of the Robot Station. After that the Robotino 2 removes the pallet from the stock, and
transports it to the next outline. Then the Robot Station starts the cycle again. Between the cycles the Robot
Station and Robotinos switch to the next pallet position, stock position, and outline one after the other. In
this case all positions will be tested in standalone mode. There is only one pallet in the system in the same
time. The operator should remove manually the delivered pallet from the outline, and place a new empty
pallet on the input slide.
Sequence of robot station and robotinos

 First the station initializes the variables [1].
 Then it waits for an empty pallet on input slide [10].
 The station sends the Robotino 1 to move the empty pallet to Robot Station [15].
 If there is an error with the communication between Robotino 1 and the PLC:
The station jumps back to Idle state [10].
 And waits until the Robotino 1 transports the empty pallet to the Robot station [20].
 Then it waits until the workpiece arrives at the end of input slide [100].
 The Robot moves the pallet to the next empty pallet place [105].
 And waits until a workpiece arrives at conveyor belt [110].
 Then the Robot moves the workpiece to the next free place of the pallet [115].
 And calculates the next workpiece position [120].
 If there is still a free place on the pallet:
The station jumps back to insert a new workpiece [100].
 Then the station waits until output slide of the Robot is free [125].
 After that it lifts up the pallet stopper [130].
 And the Robot moves the commissioned pallet to the output slides [135].
 Then waits until the Robot finishes the task [140].
 After that the station writes the RFID data into the pallet [145].
 And waits until the writing is finished [150].
 Then it lifts down the pallet stopper [155].
 And waits until the pallet arrives at the bottom of output slide [160].
 Then calculates the next pallet place [165]. The station switches between the pallet position one after
the other to check all positions.
 If all pallet places have been already used, starts with the first place again [170].
 Then the station sends the commissioned pallet to the stock with Robotino 1 [175].
The station jumps back to sending the task to Robotino 1 [175].

Process description
 And waits until Robotino 1 finishes the task, and arrives back to Robot Station [180].
 After the Robotino 1 finishes the task, the station calculates the outline position [185].
 If Robotino 2 is ready, Robotino 2 moves the pallet from the stock to the outline [190].
 And waits until Robotino 2 finishes the task, and arrives back to Robot Station [195].
 After the Robotino 2 finishes the task, the station calculates the outline position [200].
 After the pallet arrives at the bottom of the outline slide (RFID tag is detected), the station reads out the
RFID data from the pallet [205].
 And then the station calculates the next storage and output position [250]. The station switches
between the storage, and output positions one after the other to check all positions.
 If all storage positions, or all outlines have been already used, start again with the first storage position
or outline [255].
 Then jump back to Idle state [10] from an empty step [300].

Process description
2 1
1
140
Initalize variables
Wait until robot task
finished
Robot finished the

task
10 145
Write RFID data into
Wait for Auto Mode
pallet
Station in standalone mode, and buffer

and storage are empty
15 150
Send Robotino 1 for an Wait RFID write
empty pallet finished
RFID write finished

Robotino 1 is busy Error in Robotino 1
(started the task) communication 155
20 Lift down the pallet
Empty: Wait until stopper
Robotino 1 finished
Error in Robotino 1 160

Robotino 1 is ready
communication Wait until pallet at
100 slide end
Wait for empty pallet Pallett stopper in lower position

on Robot slide and pallett at slide end
Empty pallet is on 165

Robot's input slide Switch to the next
105 pallet position
Move the empty pallet The next pallet position is

to next pallet position stored in byPalPos
Robot finished the 170

task If next pos. > 4 change
to pal. Pos 1
110
Empty: Wait for
workpiece at conveyor Next storage position is free, and
Robotino 1 is ready
Workpiece available 175

at conveyor belt Send pallet to the After that the Robotino 1 will go back to
115 stock with Robotino 1 Robot Station
Move workpiece to the The next position on pallet is

next position on pall. stored in byPalIndex
(started the task) communication
Robot finished the
task 180
120 Empty: Wait until
Robotino 1 finished
Switch to the next
position on pallet.
Robotino 1 is ready Error in Robotino 1

communication
The index is 1 again Else
125
Empty: Wait for Robot
outslide is free
Robot's output slide is 185

free Calculate the outline
130 position
Lift up the pallett

Robotino 2 is ready
stopper
Pallett stopper in 190

upper position move pall. to outline
135 with Robotino 2
Move the pallet to

output slide
(started the task) communication
2 1
5 3 4

Process description

Process description
6.9.2 MES mode of Robot Station

In MES mode there are three tasks (empty tray insertion, commissioning and delivery of commissioned
pallet). The station tries to avoid serving the same task twice in a row. The empty tray insertion has the
highest priority, then the commissioning, and the delivery.
The first task is inserting the incoming empty pallet to a free pallet place. If there is an empty pallet on input
slide, and there is a free pallet place, the station moves the pallet to the free place, and registrates the
insertion in MES server.
The second task is the commissioning. If there is a pallet on a pallet place, a workpiece on the conveyor, and
the last insertion was more than 1s before, the Robot asks for an insertion task form MES, and moves the
workpiece to the specific place.
The third task is the delivery of commissioned pallet. If there is a pallet at a pallet place, the output slide is
free, and the last delivery was more than 1s before, the Robot ask for a delivery task from MES, and it moves
the specific pallet to the output slide.
Sequence of empty pallet insertion

 If there is an empty pallet on the input slide, and there is a free pallet place, the station searches for the
next free pallet place [100].
 If there is no free place:
 The Robot moves the pallet from the input slide to the specific pallet place [110].
 Waits until the Robot finishes the task [115].
 After the Robot finishes, the station checks the return code from the Robot [116].
 After the return code is 0 the station books the pallet in pallet buffer of MES server (M100.31) [120].
 Then the station waits for the answer from MES [125].
 After that the station will be on Idle state [10].

Process description
10
MES mode is active, there is an empty pallet on

input slide, and one of the pallet places is free
100
Search for the next
free pallet place
There is a free place Else
110
Move the pallet from
the input to the place
115
Wait until Roboto
finishes the task
Robot finished the

task
116
Check robot return
code
Return code = 0
120
book pallet on MES
pall. buffer (M100.31)
125
Empty: Wait MES
request finished
Answer received

Process description
Sequence of commissioning a pallet

 If there is a workpiece on the conveyor belt, there is a pallet on a pallet place, and the last workpiece
insertion was more than 1s before, the station registrates the start of commissioning [200].
 Then it asks for a commissioning task from MES (M100.2) [205].
 And waits for the answer [210].
 If there is no task for commissioning:
 The station asks the MES, where to place the workpiece (M101.35) [215].
 If there is no place for insertion:
 The station sends a “Task started” message (M100.10) to the MES [225].
 Then the station moves the workpiece to the pallet [250].
 And waits until the Robot finishes the task [255].
 Checks the return code from the Robot [256].
 After the return code is 0, the station removes the workpiece from the FIFO of MES server (M100.37)
[260].
 And waits for the answer from MES [265].
 Then the station sends a “Task finished” message (M101.1) [270].
 After the answer received, the station will be on Idle state [10].

Process description
2 1
10
230
Empty: Wait MES
request finished
MES mode is active, there is a workpiece on
conveyor, other is a pallet, and last workpiece
insertion was more than 1 sec before. Answer received
200 250
Registrate the start of Move the workpiece to
insertion the pallet
205 255
Check if order in MES Empty: Wait until
available (M100.2) robot finish
Robot finished the

task
210 256
Empty: Wait MES Check Robot return
request finished code
Answer received Return code = 0
There is a task for 260

Else
Insertion
Remove workpiece
215 from FIFO (M100.37)
Ask MES, where to

place wp. (M101.35)
265
Empty: Wait MES
220 request finished
Empty: Wait MES

Answer received
request finished
270
Answer received
Send "Task Finished"
There is a place for (M101.1)
Else
insertion
225
Send "Task Started" 275
(M100.10) Empty: Wait MES
request finished
Answer received
2 1

Process description
Sequence of delivering the commissioned pallet

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

Process description
2 1
10
355
Move commissioned
pallet to out slide
MES mode is active, there is a pallet on pall. place,
output slide is free, and last delivery was more than
1 sec before.
300 360
Registrate the start of Empty: Wait until
delivery robot finishes
Robot finished the Robot finished the

task task
305 361
Check if order in MES Check Robot return
available (M100.2) code
Return code = 0
310 365
Empty: Wait MES Write RFID datat into
request finished pallet
Answer received
370
Ther is a task Else
Wait RFID write
315 finished
Search for the pallet to

RFID write finished
move (M100.30)
375
Lift down pallet
320 stopper
Empty: Wait MES

request finished
380
Answer received
Wait until pallet at
325 slide end
Send "Task started" Pallett stopper in lower position

(M100.10) and pallett at slide end
390
Update buffer in MES
330 (M100.31)
Empty: Wait MES

request finished
395
Answer received
Empty: Wait MES
345 request finished
Lift up pallet stopper Answer received
400
Send "Task fininshed"
350 (M101.1)
Wait pallet stopper in Pallet stopper in

upper end position upper position
Pallet stopper in 405

upper position
Empty: Wait MES
2 1 request finished
Answer received

Process description
6.9.3 MES mode of Robotino 1

In MES mode there are two tasks for Robotino 1 (commissioned pallet transportation from Robot Station to
Robotino Storage, empty tray transportation to Robot Station). The commissioned pallet transportation has
a higher priority.
If a pallet is on the output slide of Robot Station, the Robotino asks the MES about next task. If there is a
task, the Robotino transports the pallet to a free storage position, and registrates it in MES. After that the
Robotino moves back to Robot Station.
If an empty pallet is available on the input slide, and the input slide of the Robot Station is free, the
Robotino moves the empty pallet to the Robot Station. In this case the Robotino does not have any
communication with the MES server.
Sequence of commissioned pallet transportation to storage

 If a pallet is on the output slide of Robot Station, the Robotino asks the MES about next task (M100.2)
[200].
 And waits until the answer received from MES [210].
 If there is no task:
 Then the PLC searches for a free place in Robotino Storage [215].
 Sends a “Task started” message (M100.10) to MES [220].
 Then the Robotino moves the commissioned pallet from the Robot Station to the Robotino Storage
[230].
 And waits until the Robotino is busy [235].
 If there is a communication error between Robotino and PLC:
The station jumps back to send the task again [230].
 Then the station waits until Robotino finishes [240].
The station jumps back to send the task again [230].
 Then the PLC books the Robotino Storage position in MES server (M100.31) [245].
 Then sends a “Task finished” message (M101.1) to MES [255].
 Then the Robotino will be on Idle state.

Process description
2 1
10
MES mode is active, there is a pallet on output slide 230

at Robot Station, and there is a free place in the Robotino moves the
storage pallet to sock.
200
Ask for a task from MES
(M100.2) 235
Empty: Wait until
Robotino is busy
210
Empty: Wait MES Error in Robotino
Robotino is busy
request finished communication
240
Answer received
Empty: Wait until
Robotino finished
Ther is a task Else
215 Error in Robotino

Robotino finished
Find next free shelf in communication
storage 245
Book pallet on MES
Free place found
stock buffer (M100.31)
220
Free place found
Send "Task started"
(M100.10) 250
Empty: Wait MES
request finished
225
Answer received
Empty: Wait MES
request finished 255
Send "Task finished"
Answer received
(M101.1)
2 1
Free place found
260
Empty: Wait MES
request finished
Answer received

Process description
Sequence of empty pallet transportation to the Robot Station

 If an empty pallet is available on the input slide, and the input slide of the Robot Station is free, the
Robotino moves the empty pallet to the Robot Station [100].
 And the PLC waits until the Robotino is busy [105].
The PLC jumps back to send the task again [100].
 Then the PLC waits until the Robotino is finished [110].
 After the Robotino finishes, the station will be on Idle state [10].
10
MES mode is active, there is a pallet on input slide, and

the input slide of Robot Station is free
100
Robotino moves
empty pallet to Robot
105
Empty: Wait until
Robotino is busy
Robotino is busy Error in Robotino

communication
110
Empty: Wait until
Robotino finished
Robotino finished Error in Robotino

communication

Process description
6.9.4 MES mode of Robotino 2

In MES mode the Robotino 2 has only one task (Transportation of commissioned pallet from Robotino
Storage to outline slide). Before the delivery the PLC asks the MES server about the destination of the pallet.
If the destination is not defined, the PLC selects the next free output slide.
Sequence of pallet delivery to output slides
 If there is a free output slide, and a pallet in the Robotino Storage, the Robotino asks for parameters of
pallet delivery (M100.41) [100].
 If there is no task for delivery:
 After that the Robotino selects the destination slide. If there is a predefined slide, the Robotino selects
that. If there is not a predefined slide, the Robotino selects the first free output slide from the left [115].
 Then the PLC sends a “Task started” message (M100.10) to the MES [120].
 The Robotino transports the pallet form the storage to the selected output slide [130].
 And the PLC waits until Robotino is busy [135].
 Then the PLC waits until Robotino finishes the task [140].
 The PLC updates the Robotino Storage buffer in MES (M100.31) [145].
 Then the PLC sends “Task finished” message (M100.31) to MES [155].
 After the answer is received, the station will be on Idle state [10].

Process description
2 1
10
150
Empty: Wait MES
request finished
MES mode is active, there is a free output slide, there is
a pallet in the Robotino storage
Answer received
100
Get parameters for 155
delivery (M100.41) Send "Task finished"
(M101.1)
110
Empty: Wait MES 160
request finished Empty: Wait MES
request finished
Answer received
Answer received
There is a delivery task
Else
from storage
115
Select output slide
120
Send "Task started"
(M100.10)
125
Empty: Wait MES
request finished
Answer received
130
Robotinio moves the
pallett to out. slide
135
Empty: Wait until
Robotino is busy
Robotino is busy Error in Robotino

communication
140
Empty: Wait until
Robotino finished
Robotino finished Error in Robotino

communication
145
Update storage buffer
in MES (M100.31)
2 1

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

Process description
7.2 Modules in use

The conveyor system is made up of a number of different function modules, some of which are also used in
the field of MPS-Plus.
 Pallet
 Work pieces
7.2.1 Pallet
Responsible for the transport of 4 processed or unprocessed cylinders. The palette can be moved from the
robot by means of the reception aid at the center of the palette. On the bottom side there is the RFID Sensor.
Measurements: 164 x 164 mm
Pallet 1BPW
7.2.2 Work pieces

There are 3 different work pieces, they distinguish in their color – red, black and silver work pieces are
available.
Work pieces

8 Pneumatic
8.1 Pneumatic supply
The pressure in the supply line must not exceed 10 bar. A fine filter has to be installed, to prevent
contamination by rust or similar.
A stop cock is required for the supply of the installation.
The pressure regulators installed in the system, should be set in between 5 and 6 bar. The filter and water
separators require maintenance according to the instructions of the documentation of these components.
Service unit
Position Name
1 Ordernumber 152894
2 Ordername D S-PWR-LFR

9 Electrical System
To operate the system it is required to connect all of the supply cables and communication lines included.
The cables used to program the system are explained additionally.
To give you a better survey of the being lines used in the plant, these are explained in the following.
9.1 Power supply

The devices are delivered together with the respective power supply plugs, protectively contact covered, in
case they require power supply.
The customer must ensure that the power supply is earthed correctly and is equipped with a fault current
monitor.
If it is required for several devices to be in operation at the same time, it is possible to connect these to a
switchboard containing distribution board, provided that the permissible maximum rating is not exceeded.
Each station contains its own individual EMERGENCY STOP switch, which at first reacts to its respective
station only. It has to be clarified in advance, if a central ROOM EMERGENCY STOP switch is required.

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

Electrical System
9.3 Wiring
The wiring within the station and the wiring to the other stations are explained in the following.
9.3.1 I/O-Components
The modules from the station are pluggable connected via I/O-terminals to the
I/O-cards from the control.
So that a perfect communication can be ensured, the I/O interface is standardized. The I/O terminal is at all
work positions at the disposal.
I/O-Terminal
Technical data
Plug type IEEE 488 24 pins
Inputs 8
Outputs 8
Current consumption Max. 1A/PIN
Power supply 24 VDC

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

Electrical System
Festo Didactic GmbH & Co. KG

Rechbergstraße 3
73770 Denkendorf
Germany
Internet: www.festo-didactic.com
E-mail: did@de.festo.com

Prolog Manual A003

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ProLog®

2 © Festo Didactic ProLog

1 General safety instructions __________________________________________________________________ 6

3 © Festo Didactic ProLog

4 © Festo Didactic ProLog

© Festo Didactic ProLog 5

General requirements for safe operation of the devices:

6 © Festo Didactic ProLog

© Festo Didactic ProLog 7

1.2 Safety sockets

Colour Function Colour Function

Voltage greater than SELV 24 V DC

Protective conductor Safety extra-low voltage,

8 © Festo Didactic ProLog

1.3 Handling the system

1.3.2 Safety precautions in standard operation

1.3.3 Dangers due to electric current

© Festo Didactic ProLog 9

1.3.4 Dangers due to pneumatic energy

1.3.5 Maintenance – Servicing – Malfunction removal

1.3.6 Organizational measures

1.4.2 Training operations

1.4.3 Outside training operations

1.4.4 Obligations of the operating company

Personnel should be tested at regular intervals for safety-conscious work habits.

1.4.5 Obligations of the trainees

10 © Festo Didactic ProLog

2.2 Intended use

2.3 Important notes

11 © Festo Didactic ProLog

12 © Festo Didactic ProLog

2.5 Customer system

Overview prolog-factory system

Position Description Position Description

1 Triple stack magazine station 8 Sorting station

2 Testing station with colour sensor 9 Log area

3 Processing station 10 Robotino 2

4 Pick and place station 11 Robotino 1

5 Fluid muscle station 12 Commissioning station

6 Storing station 13 Connecting conveyor 3

© Festo Didactic ProLog 13

2.5.1 Triple stack magazine station

Triple stack magazine station

14 © Festo Didactic ProLog

2.5.2 Testing station with color sensor

Testing station with color sensor

© Festo Didactic ProLog 15

2.5.3 Processing station

16 © Festo Didactic ProLog

2.5.4 Pick and place station

Pick and place station

© Festo Didactic ProLog 17

2.5.5 Fluid muscle station

Fluid muscle station

18 © Festo Didactic ProLog

2.5.6 Storing station

© Festo Didactic ProLog 19

2.5.7 Separating station

20 © Festo Didactic ProLog

2.5.8 Sorting station

© Festo Didactic ProLog 21

2.5.9 Commissioning station

22 © Festo Didactic ProLog

2.5.10 Log area