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SW-Development |
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… es gibt nichts, was nicht optimiert werden kann!
Mögliche Lösungen der SPS-Programmierung In vielen Fällen meiner Praxiserfahrung habe ich festgestellt, dass gerade im Bereich Sonder-Maschinenbau eine hohe Effizienz im Reduzieren auf das Wesentliche in der Programmiersprache und Struktur zu einer Verkürzung/Verringerung der SPS-Laufzeit bzw. des SPS-Speichers führt und damit eine finanzielle Einsparung ermöglicht. In den folgenden Seiten möchte ich praktische Ideen im Bezug auf Digitalen Zwillingen aufgreifen und den interessierten Leser zum Nachdenken bringen. |
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... there is nothing that can’t be optimized!
Possible solutions of PLC programming In many cases of my practical experience, I have found that especially in the field of special machine construction, specific adaption of the PLC-Language and structure leads to higher efficiency in shortening PLC cycle time or rather reducing the PLC memory, and thus makes a financial savings - when selecting the CPU family - possible. In the following examples I would like to present digital twins related to real industrial plants and convince readers to modify the development focus if necessary. |
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Shaping Preheated Thermoplastic In recent years shaping by the vacuum process has gained importance. For molding of complex components a preheated thermoplastic sheet is placed over a master model and preformed. The air is then evacuated through ducts in the mold so that the sheet is drawn (by suction) into the mold, and thereby a desired shape is obtained. In this plant before heating process the mold outline is scanned and then accordingly sprayed with silicon which enables a smooth component separation from the mold. (Tested: 06/2024) |
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Winding of Non-Pneumatic Tires (NPT) A strap of a winding non-pneumatic tyres produced by a preheated extruder, extracts an unvulcanised carbon black rubber at a pre-defined constant speed. The extracted strap has a specific cross-section. The winding equipment consists of two servomotors, a master motor and a slave motor. The master motor rotates a deformable winding hub (x). The slave motor moves a rubber steering device back and forth, and is y=f(x). Due to the winding the tyre diameter becomes larger and larger which results the master motor to rotate correspondingly slower and thus the steering device. (Tested: 02/2024) |
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This machine carrier grants the possibility to form a double-sided notch on a work piece element. Precision is required since distance between notch and work piece edge must be kept. Finally, the work piece element is labelled at the very end of the carrier. Plant description: The element arrival is captured by a swift sensor that registers the current position. The machine carrier masters 2 tools-chains that form the double-sided notch. The number of work piece elements per second depends on the machine speed and is limited, otherwise independent. (Tested: 12/2023) |
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Syringe Roller Picker 2D (SCL) Handling: The movement of the vacuum gripper which picks up syringes from an input blisters-conveyor, and places them on a free output belt-conveyor is implemented by so called Roller-Picker 2D (vertical and horizontal). The vacuum gripper can be tilted pneumatically up and down by 90°. Feeding: The syringes are picked up vertically from an input conveyor, and placed horizontally on an output conveyor. Separation of coming blisters on input conveyor is done by an electrical pre-stopper and stopper. The machine has a safety area which allows manually feeding of syringes on a tool magazine. The Roller-Picker can be then enabled to pick up those syringes, and place them on the output belt-conveyor. (Tested: 08/2023) visit <Dokumentation> to watch MP4 video.
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Cartesian 3D of a 3-Axis for 3 Sector Gasketting Plant (SCL) In this plant circular movements are possible. As a result, you improve cycle time and smooth movement of your plant. In our case the plant consist of a row of pallets each one can carry up to 32 work pieces of witch enables you to gasket up to 3 sectors of different groove samples. There are 3 programme choice available hence a total of 9 different samples. To ease the commissioning of each work piece sample you can set it to 1 per sector - i.E. a total of 3 - the pallet. (Tested: 04/2023) |
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Liquid Handling Concept including CIP (SCL) This plant sterilizes beverages by using the Short Term Heating Principle. A function combines time and temperature so-called Pasteurization-Unit (PU = minutes x 1,83^72°C - 60°C) determines the validity of the product. In addition to the usual manual/automatic operating modes, two main functions are run: Production, and CIP (clean in place). The production consists of: filling sterile buffer tank 1 (SBT1), filling, and heating circular flow with water, following the PU-Principle filling, and heating circular flow with product, filling SBT2, then production with filler. The CIP function, sterilizes all valve seats and pipes with Lye and water. (Tested: 01/2022)
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Pump Case and Securing Plate the Final placement (SCL) The pump case is taken from a two-column box and placed on WP-Conveyor. Then the pump which is connected to the securing plate is picked up from a second conveyor to be placed inside the pump case that is on the first conveyor. The whole component is then transported to a screwdriver-station for final assembly. (Tested: 03/2021)
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Pick & Place Annular Spring into Blister Tray (SCL) By means of 3 positioning axis, and 2 finger gripper axis an annular spring is to be picked up from one blister-tray, transferred through 4 processing station, and then be placed on a second blister-tray. Processing place 1: part available check, 2. Alcohol cleaning pool, 3. UV-coating resin, 4. UV-coating drying chamber. Machine purpose: coating untreated annular spring then under UV-radiation the coated spring to quickly dried it up. The smart S7-Structure demonstrates how fast and easy it is to match available applications of assembly system to a new ones. (Tested: 11/2020)
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Practical Pick & Place plus Batching for Packaging machines (SCL) A 4-servo-axis-gripper is to pick up two different type of vacuum filters from two infeed conveyors, to place them on a pallet at a batching station, and when job done to transfer the pallet to a packaging machine. Both conveyor have the same priority witch means the gripper moves to the first one that signal “ready” and then to the other. If the other one dose not signal “ready” the gripper will continue with the first one. There are 3 ways out: 1. default (normal way), 2. faulty (Nok) or a Print-Test selected by the operator, 3. quality assurance test (QA) selected by the operator. The default way for a filter to be placed at the batching station requires: Top-View-Test (camera 1), QR-Code-Scanning, Scanned-Code-Printing, Text-View-Test (camera 2). (Tested: 08/2020)
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CEA Multi-Daylight Hydraulic H-Press (SCL) A wide range of sheet metal shaping operations are implemented by hydraulic press. The purpose of the aforementioned issue is not only to develop an optimized PLC-Code for this range but also to think about a clear structure to facilitate future or further software development. The same applies to operating and monitoring the press function (so-called HMI). The above application category focuses on dynamics, and safety technology of a down stroking hydraulic presses. (Tested: 10/2019)
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Spring Quality Control (SCL) The spring quality inspection occurred by means of 4-slave modules and 1-master module. As soon as all modules declare readiness to start the master module sends the required enable signal. However, the module sequence responses only if its spring index position - reading out of a shift register - delivers true-signal, otherwise each one of them are ready immediately. The following sample program (S7-Code, and interactive HMI) based on a sort of RTT-principle (Round-Trip Transport) shows a practical solution for such technology. (Tested: 06/2019)
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Storage and Retrieval Control of 2 High-Bay Storage Warehouse (SCL) The system consist of 4 belt conveyors on a stacker crane (STC), and 2 High-Bay Storage system (HBS). The truck conveyor can be fully or partly loaded with small or large plastic storage boxes. During stacker crane loading each box is automatically scanned, and copied into so-called "box-data". The loading request is administered by a Material Flow Computer (MFC). In order to reach an equal charge of both High-Bay-Storages (HBS1/HBS2) a ‘Round-Robin principle’ is used. If one of the box-data is not plausible, the entire commission is then not valid. In this case the storing procedure will stop, otherwise the PLC copies the data to 4 belt conveyors box-data. Each data-box holds: company initial, storing place number, storing depth, HBS number, goods weight, and a storage box type (large/small). Furthermore, each conveyor has two light barrier one towards HBS1, and one towards HBS2. Once the box arrives at one of the light barrier, the box-data is transferred from previous box-data to the current box-data. After each box transfer whether to HBS1 or to HBS2, the PLC sends a message in reply to the MFC request that transfer is correctly done. See also Documentation/Videos. (Tested: 03/2019)
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Electrical Screw Spindle Press (SCL) Machine presses can be hazardous, so safety measures must be taken. Electrical presses may have various drive systems. One of them could be provided with servo drive controller. The above-named press discuses a longitudinal force witch can be dangerous for mechanical elements caused by wrong handling. For this reason a desired safety motion (DSM) is necessary to protect the machine. This could be achieved e.g. in manual mode by using a plausibility-check bevor moving to a target position. The function block DSM_DATA_SET includes a program code that prevent undesirable press movement. The FB is a multitude programmable interface (Multi Pro) that controls your HMI press procedure entry, and in case of implausible values it triggers an error within the first plc cycle after start. The second plc cycle transfers the target positon, and in the third cycle velocity. Note: the function jogging has higher priority than positioning. (Tested: 12/2018)
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Motion Control V4.0 software development of master and slave Axis (SCL) This Project describes the handling of function blocks FB TO EPOS - elementarily positioning an axis, and FB TO GEAR synchronous-axis that can be used for positioning and synchronous axis tasks. Number of synchronous axes depends on the CPU capability. In this example there are three master axes (here rotatory and linear), and two slave synchronous axes. Click the above title to get more info. As a German reader you would find further information by clicking the website link Documentation (Tested: 09/2018)
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This prototype can be a model of a final product using transport technology for heavy-weighted objects. By means of servomotors the model uses EPOS (simple positioning) methods to reach its targeted positions witch is often to find in assembly modules. In order to avoid cumulative error the drive actual position at a reaching target is then set to null; it means the new actual position is now equal <+0.0>. The light barriers used in the model are solely to query results at target position, and if necessary to provoke a positioning error. (Tested: 01/2018)
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40 tons Spotting press & interactive HMI. (AWL) This program code shows a possibility of operating and monitoring a large hydraulic form press. The operating is possible in a manual or automatic mode. A pressed demi-object leaves in the upper und lower forms visible traces (spots) where a correction is thereafter required. This happens by means of an exact distance measuring between 4, 3 or 2 corners - so called parallelism test. If the pre-set tolerance is overreached, the two parts form opens and travel outwards the press for a correction. Else, the press elevates its plunger to its access position TDC (top dead centre). The press is then ready for a new cycle. The HMI is a Mobile panel without a dynamic set point wheel. Here, the dynamic set points is realized by a slider. (Tested: 12/2016)
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Teil eines Simulationsprogramms. (AWL) (Getestet: 05/2015)
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Beispiel einer Schlamm-Trocknungs-Anlage (STA) (AWL) Um den Wirkungsgrad einer Verbrennungsanlage zu erhöhen, wird aus Klärschlamm Trockengut erzeugt. Dies geschieht mittels sieben Produktionsgruppen. Näheres dazu siehe: Dokumentation (Getestet: 02/2014)
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Messung analoger Signale an einer SPS mit nur einem digitalen Eingang ! (AWL) Eine äußerst wirtschaftliche Möglichkeit, analoge Größen mittels digitalen Eingangs an einer SPS zu erfassen. Dazu siehe FC108 (getestet: 08/2012)
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Programmablaufplan (PAP) (AWL) Aufruf einer Schrittkette via eine Funktion (Stand: 01/2012)
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Lösungsmöglichkeit in der Fördertechnik (with zero-pressure conveying) (AWL) Die Standardfunktion FC2 bietet eine kompakte Lösung für drei Rollenförderer, die sich innerhalb der Montagemaschine befinden und bildet die notwendige Schnittstelle dazu. Der Eingangsförderer RB01, der Arbeitsförderer RB02 und das Ausgangsförderer RB03. Zusätzlich verfügt der Arbeitsbereich über eine Reihe von Lichtschranken, die für die Stopppositionen der Bearbeitungsstationen zuständig sind. (Stand: 01/2011) Näheres dazu siehe: Technologischem Montagemaschine sowie Dokumentation (Stand: 01/2011)
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Short Term Heating Concept (Process Measurement and Control) (SCL) FB MAIN GLB (multi-instance FB) links by way of using HMI the requested operating modes of the plant. FB SEQ200 GLB controls the process phases. A graphical flow chart help the operator to find out at witch stage an error has been occurred, what has been completed or what is next to come. This plant does not exist but represents based on its simulation code to a certain degree the real one - so called digital twin. (Tested: V2.0 06/2021)
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Click the blue-title-link to get to a desired PLC-Program. Note: Interactive HMI means that some of the touch-buttons involve a link to another HMI screen. |