Sequential systems with CIROS Mechatronics and CoDeSys 2.

Testing Station
1.

Description

The Testing Station is a part of Festo Modular Production System. His function is receive the
workpiece from Distribution Station, detect the type of piece, by color and height, and
depending on the test
result, the workpiece is
Testing Station
to be ejected or
Air layer ramp
transferred
to
the
neighbouring station..
There are four types of
workpiece: red, black,
silver and blue.
The Station has two
slides. The higher, with
slope, equipped with a
cushion of air for easy
sliding those pieces that
have to go to the next
station, called air layer
ramp. And the lower,
installed flat, to store up
to 5 pieces ejected, that
havent to go to the
next station.

2.

Lower slide

S1_Start
S2_Stop
S3_Man_Aut
S4_Reset
P1_Start_Light
P2_Reset_Light

Study of the behavior of the stations sensors

The place where the workpiece will be

charged has installed two detectors:

Det_1B2_Up_Lift_Cyl

Part_AV: Capacitive sensor, which detects

(1) all kinds of workpieces and must be used
to start the process.

Reflection
Mirror

B2_Workpiece_Not_Black:
Reflective
object sensor, wich detects (1) workpieces
red, silver or blue, and (0) if the workpiece
is black.

Part_AV

Det_1B2_Down_Lift_Cyl
B2_Workpiece_Not_Black:
1 when red, silver or blue
0 when black

B4_Safety_Det

Sequential systems with CIROS Mechatronics and CoDeSys 2.3

At the top of the lift cylinder, has mounted a resistive transducer (B5_WorkPiece_Height_OK)
coupled to a comparator, measure height, detects (1) workpieces red, black or silver, and (0) if
the workpiece is blue.

B5_WorkPiece_Height_OK:
1 when red, black or silver
0 when blue

Cyl_2M1_Eject_Out and his

Det_2B1_Eject_Cyl_In

Note that the lift cylinder has

raised the workpiece, the
reflective
object
sensor
(B2_Workpiece_Not_Black) and
the eject cylinder.

So, the conditions for detecting the type of workpiece can be summarized in the following
table:

Workpiece type

B2_Workpiece_Not_Black B5_WorkPiece_Height_OK
Red

Silver

Black

Blue

So when defining the sequence there are several discrimination options, on the one hand can
be detected red and silver on the other hand can be detected independently black or blue.
In the example program that incorporates the station in CIROS, pass up red, black and silver,
and blue are rejected. But in practice we could program other variations such as pass up only
black or only red and silver, and discard the rest.

Sequential systems with CIROS Mechatronics and CoDeSys 2.3

3.

Variables

Input Variables
Name

Type

Description

Part_AV

BOOL Workpiece is available

B2_Workpiece_Not_Black

BOOL Workpiece is RED, BLUE or SILVER but NOT BLACK

B4_Safety_Det

BOOL The transporter arm of earlier station is in the work area

B5_WorkPiece_Height_OK

BOOL The present workpiece has an OK height

Det_1B1_Up_Lift_Cyl

BOOL Detector: Lift Cylinder is UP

Det_1B2_Down_Lift_Cyl

BOOL Detector: Lift Cylinder is DOWN

Det_2B1_Eject_Cyl_In

BOOL Detector: Eject Cylinder is IN

IP_FI_Next_Station_Free

BOOL

S1_Start

BOOL Start Button Normally Open

S2_Stop

BOOL Stop Button Normally Close

S3_Man_Aut

BOOL Key Selector: 1=Manual o 0=Automatic

S4_Reset

BOOL Reset Button normally Open

Ouput Variables
Name

Type

Description

Cyl_1M1_Lower_Lift

BOOL Lift Cylinder is Lower

Cyl_1M2_Raise_Lift

BOOL Lift Cylinder is Raise

Cyl_2M1_Eject_Out

BOOL Eject Cylinder is Out

Ramp_3M1_Air_Layer

BOOL Air Layer Ramp is ON

IP_FO_Busy_Station

BOOL Occupied Station

P1_Start_Light

BOOL Light of Start Button is ON

P2_Reset_Light

BOOL Light of Reset Button is ON

P3

BOOL Not in use

Sequential systems with CIROS Mechatronics and CoDeSys 2.3

4.

Description of the sequence

The mode of operation of the testing station has to be as follows: Receive a workpiece for the
previous station, pass up red and silver to the next station through air layer ramp and
ejected black and blue to the lower slide.
By putting RUN, turn on RESET indicator light, the station waits for the user to press the RESET
button.
Pressing RESET = 1, move station to initial position, means lift cylinder in low position and the
ejector and air cushion to 0. If you press RESET when we have uploaded workpiece at the
station, this will be rejected at the lower slide regardless of color.
Then turn off RESET indicator light and turn on START indicator light, inviting to be pressed.
When the START = 1 turn off START indicator light, and if no item loaded in the station, it
remains rest until is detected workpiece (PART_AV).
When there is workpiece (PART_AV = 1), the work starts from the testing station. If the
reflective object sensor (B2_Workpiece_Not_Black = 0) means that the piece is black, and can
be ejected acting eject cylinder (Cyl_2M1_Eject_Out = 1). Otherwise reflective object sensor
(B2_Workpiece_Not_Black= 1), can not discriminate the type of piece yet, so verify that there
is no obstacle that prevents acting lift cylinder (B4_Safety_Det), indicate that the station is
busy (IP_FO_Busy_Station = 1), and then move up the lift cylinder (Cyl_1M2_Raise_Lift = 1)
until (Det_1B1_Up_Lift_Cyl) detects.
When the elevator is located above (Det_1B1_Up_Lift_Cyl). If the resistive transducer
(B5_WorkPiece_Height_OK = 1) means that the piece is red or silver, and can be pass up to the
next station acting eject cylinder (Cyl_2M1_Eject_Out = 1), and the air cushion of the ramp
(Ramp_3M1_Air_Layer = 1), and finally moving down the lift cylinder (Cyl_1M1_Lower_Lift =
1).
Otherwise resistive transducer (B5_WorkPiece_Height_OK = 0), means that the piece is blue
and has to be ejected moving down the lift cylinder (Cyl_1M1_Lower_Lift = 1) until
(Det_1B2_Down_Lift_Cyl) detects and then the workpiece can be ejected acting eject cylinder
(Cyl_2M1_Eject_Out = 1).
At this point, the station remains rest until is detected workpiece (PART_AV), and indicates
that is available (IP_FO_Busy_Station = 0).
STOP button: If you press STOP (NT) mid-sequence, the system stops after current motion,
turn on START indicator light. If START is pressed the START indicator light turn off and the
sequence continues from where it left off (the STOP action described is different from the
CIROS program, where the piece is always ejected after a STOP).
Key MAN_AUT: When automatic position MAN_AUT = 0, after having started, the station
sequence starts automatically when detects new workpiece. If MAN_AUT = 1 (Manual) when
new workpiece is detected, must press START to initiate the station sequence. The pilot press
the START button turns inviting.
4