Showing posts with label KnowHow. Show all posts
Showing posts with label KnowHow. Show all posts

How to use DASSIDirect DAServer Together with Siemens S7-200 PLC?

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Introduction

This technote will go over the steps necessary to setup communication between the new DASSIDirect DAServer and a Siemens S7-200 PLC.

The TechNote consists of 4 parts:

Configure the S7-200 PLC
  • Configure the DAServer
  • Test the Communication
  • Memory Areas in the S7-200 PLCs and How to Access Them Via
    DASSIDirect
Configure the S7-200 PLC
  1. Start Step7-Micro/Win 32. Create a new project or load
    your existing one (Figure 1 below):


    Figure 1: Step 7 - Micro/WIN32 - Project1 Dialog Box

  2. Click on Tools and then select Ethernet Wizard.
  3. Step through the wizard:





    Figure 2: Ethernet Wizard
  4. Click Yes when asked to use symbolic addressing. Otherwise the wizard
    cannot continue:

    Figure 3: Click Yes

  5. Enter the module position of the CP243-1.
    If you are uncertain about the position, click the button Read Modules.
    Otherwise you can enter the number directly:


    Figure 4: Specify Module Position Dialog Box
  6. Enter the IP configuration of your CP243-1.
    Especially during the startup phase of the project, I would recommend not
    to use a BOOTP server.
    Let the module detect the connection type (Figure 5 below):


    Figure 5: Module Address Configuration
  7. Enter the numbers of connections you want to configure for the CP243-1
    Default value is 0, which would not allow communication. In this example
    I will use 2 connections (Figure 6 below):


    Figure 6: 2 Connections
    Now you have to configure the connections. Connection 0 (Figure 7 below) will
    accept all incoming client requests:


    Figure 7: Connection Configuration
  8. Always select This is a Server Connection. I recommend using the
    default TSAP's as suggested by Step7-Micro/Win32.
  9. Click Next Connection (or Prev. Connection if available)
    to step through all the connections to configure them.
    Note: If you plan to use such a connection, be sure that only one client
    tries to connect to the PLC via this connection at the same time. All other
    connection tries will be rejected.
    Connection 1 accepts only requests from the specified client:

    Figure 8: Specified Client Requests
  10. If all connections are configured click OK.
    During the startup phase of a project I would recommend not to use a CRC protection:


    Figure 9: No CRC Protection

    The wizard now needs a range in the V-Memory where to store this information.
    Step7-Micro/Win32 will suggest a valid range.
  11. Click on Suggest Address if you have planned to use this range for
    something else.
    In this case Step7-Micro/Win32 will suggest another free range that has the
    correct size to hold this data:


    Figure 10: Store Memory Allocation for Address
  12. Click Next.
    The program now has enough information:

    Figure 11: Generate Project Components
  13. Click Finish to complete the configuration:

    Figure 12: Complete the Wizard Configuration
  14. Click Yes.
    In Step7-Micro/Win32 you should now see something like the following
    figure:


    Figure 13: Step7_Micro/Win32 Window
    Step7-Micro/Win32 has created some new entries in the V-Memory, starting at
    the address as specified during the setup of the CP243-1.
  15. Download the configuration to the PLC:

    Figure 14: Download the Configuration
  16. Select all options and click OK (Figure 15 below):

    Figure 15: Download Options
  17. Set the PLC to STOP mode in order to be able to download a new configuration:

    Figure 16: PLC STOP Mode
  18. After the download don't forget to set the PLC to RUN mode again.
    This will not be done automatically:

    Figure 17: PLC RUN Mode

The PLC side is now configured.

Configure the DAServer

Configuration of the DAServer is quite easy.

Since we have created two connections in the PLC, we will also create two connections
in DASSIDirect DAServer. Connection 0 will correspond to the connection as created in Figure
7:


Figure 18: DASSIDirect Connection 0

The Remote TSAP in DASSIDirect must be the Local TSAP in the PLC configuration,
and vice versa.

Connection 1 shown in Figure 19 (below) will correspond to the connection
as created in Figure 8:


Figure 19: DASSIDirect Connection 1

The single parts of the remote TSAPs in DASSIDirect are called Remote Rack
No
, Remote Slot No and Connection Resource. This naming convention
was meant for S7-300 and S7-400 PLC's.

For S7-200 PLC's it is a little bit different. The Remote Slot No (which
is the remote slot number of the CP, not the CPU) in the DASSIDirect configuration
corresponds to the Module Position as seen in Figure 4.
The Remote Rack No should always be 0.

Another way to figure out the correct values for the remote TSAP's in DASSIDirect
is described in the following information:

Figure 20 (below) shows you how to figure out the meaning of the single parts
of the remote TSAP in DASSIDirect from a local TSAP configuration in the PLC
as seen in Figure 7 or Figure 8 (The TSAP
in Figure 20 do not correspond to the TSAP's as used in the above example. I
wanted to have different numbers for Rack and Slot in Figure 20!).


Figure 20: Remote TSAP

The TSAP in Figure 20 would correspond to the remote TSAP value in Figure
7 or Figure 8.

In this example the value for Connection Resource in DASSIDirect would
be 02, the value for the Remote Rack No would be 0 and
the Remote Slot No would be 3.

Now create your device group(s), if necessary.

For a DDE/SuiteLink connection you need to have at least one device group per
connection, for OPC it is not necessary. For to test the communication as described
below, please enter a device group called S7200.

The connection between DASSIDirect and the S7-200 PLC should now be ready to
test.

Test the Communication

In previous TechNotes we used wwclient for testing. This tool will no
longer be installed when installing ArchestrA (A²) products like InTouch
8.0 or any DAServer. If you have InTouch 7.11 installed you will find this tool
under Program Files/Wonderware FactorySuite/Common and you can use this
tool.

  1. Create a simple InTouch application with one tag.
  2. Select Special/Access Names from the main menu.
  3. Select Add.
    The Add Access Name dialog box appears:


    Figure 21: Add Access Name
  4. Enter a meaningful name in the Access field.
  5. Leave the Node Name blank if you have InTouch and DASSIDirect on
    the same node.
    Otherwise enter the nodename of the PC where DASSIDirect resides.
    The Topic Name must match the Device Group name as configured
    in DASSIDirect.
  6. Select Special/Tagname Dictionary and select New.


    Figure 22: New Tagname
  7. Select Type: I/O Integer and the access name as created in the previous
    steps.
  8. Use the item MB1 because it always exists in all S7-200 PLCs.
    Use this tag in the window you just created.
  9. Activate DASSIDirect in the System Management Console (SMC).
  10. Start WindowViewer™.
  11. Open the Diagnostic in the SMC to verify the communication:

    Figure 23: Check Communication from the SMC
    If you see a Time value that is changing, and a Client Quality
    of 00C0, your communication is fine.






CASE STUDY: Automatic Check Weighing

Labels:

automatic check weighing

The Material Handling Automation Problem

A major packer of apples wanted to install an automatic checkweigh system in their facility to automatically check weigh shipments of apples. The packer ships many different kinds of apples and the weight for various boxes created a need for carton identification. Most companies would use a simple barcode; however no barcode or RF tag was available. This challenge prevented the customer from taking full advantage of the new inline conveyor system until CASI was contacted.

The Automated Solution: Automatic Check Weighing System

CASI proposed utilizing the processing power of the 1100 check weigh controller in conjunction with a series of light curtains and color sensors to detect the size and weight of each carton, as this enabled CASI a to identify the expected weight of apples being shipped and automatically adjust the upper and lower control limits of the automatic check weighing system on the fly.

check weighing system

Apples in storage are automatically delivered to the shipping conveyor using a specialized hanging conveyor system.

inline matieral handling and weighing

Operators remove these boxes and place them on the shipping conveyor. These boxes are diverted using a pop up wheel divert to the automatic check weighing system.

automatic filling checkweigh

As the cartons enter the high accuracy checkweigher, the sensors detect the carton type and the upper and lower control limits are loaded.

upper and lower limit weighing

As the carton exists the scale, the check weigh system determines pass or fail on the over / under check weigh.

light curtain sensor checkweigh

Cartons that pass the automatic check weigh inspection are allowed to continue on to shipping.

automatic checkweighing

Cartons that fail are diverted to a manual QC inspection line.

Benefits from the new efficiencies

automation check weigh

The benefits from the new system include automatically checking for upper/lower control limits before shipping, reducing labor and manual QC involvement as well as charge backs from customers who are shorted product.

For more detail: http://www.cornerstoneautosys.com





CASE STUDY: Automatic Shipping and QC System

Labels:

pack verification

The Problem – Need a 100% accurate shipping system

CASI was approached by a manufacturer of food safety test kits with the challenge of developing a shipping system that would guarantee 100% order accuracy. Shipping labels and special paperwork would have to be printed from the system. In addition, the system would need to record a proof of fulfillment video of the entire operation.

The Solution – SolidPack Proof of Order and Fullfillment

CASI install SolidPack, a module from the SolidSuite Warehouse Control System (WCS) along with an interface to the customer’s legacy SPT ERP System.

EQUIPMENT LIST:

  1. SolidPack
  2. SolidComm
  3. SolidShip
  4. 1100 System computer with I/O
  5. Cordless handheld Scanner
  6. shipping scale
  7. Report printer
  8. Thermal Transfer Shipping Label Printer

Pick and Pack System Overview

The system starts with a custom interface into the SPT ERP system to get the order information using SolidComm. A paper pick ticket is used by the customer’s picking system as shown below:

pick ticket verify

This barcode represents the order that is being processed. The entire order is downloaded in less than 50 ms by the SolidComm system. Once the order is local, the system tells the operator to place the shipping carton on the scale. This provides the system with the tare weight for the shipping carton.

pack weigh scale

Solidpack is voice enabled and speaks up to five languages. It tells the packer to scan the first item and place it in the box. The system has an expected weight for the item and check weighs each item as it is placed in the shipping box.

verification of order ticket

As each item is placed in the shipping carton, it is verified by barcode and weigh. In addition, the system builds a proof of fulfillment video using the attached fire wire camera.

pack verify

This process continues until the carton is full.

full package verification

Special paperwork such as packing lists, instructions and collaterial material can be added at this time.

video proof packing

Once the packing list and collateral paperwork is included, the case is sealed on the scale and a shipping label printed using SolidShip. SolidShip interfaces to all carriers from each individual pack station.

packing verification

The video reports can be viewed at any time by customer service and emailed to customers with questions about their order and missing or incorrect items. Since installing the system, the customer has had ZERO mispicked or shipped items.

Benefits from the new efficiencies

Benefits from the new pick and pack system include elimination of mispicked orders, reduced labor costs due to labor statistics, faster and more predictable order processing.

For order and more information: http://www.cornerstoneautosys.com





CASE STUDY: 12M Cigarette Case Cutter

Labels:

12M cigarette case cutter

The Problem: Manual Process to Open Cigarette Cases

Retailers and wholesalers who have to cut 12M cases of cigarettes can attest to the many issues involved in manual case cutting operations. Expensive damage and high labor costs along with turnover of personnel just when they become proficient at the job is an all too common problem.

The Solution: Automatic 12M Case Cutting

CASI offers a solution to this problem in the ABOT Automatic Case Cutter. The ABOT 12 M cigarette case Cutter can automatically cut up to 1100 cases per hour without damage.

System Overview

automatic case cutter setup

Before running the system, normally the operators log in on the optional remote touch screen.

case cutter accumulation

The Automatic 12m Case cutting system is totally unattended and can accept cartons from an existing conveyor line as shown above.

automatic scanning for packaging

The optional barcode scanners can be used to identify random cases by the case code or other barcode identifier.

12m sorter

The SortMaster 200 parser / merger uses a round robin methodology to direct cases into the system.

case cutter machine

The operator easily separates the case now cut without damage.

12m case splitter

12m casecutter

Benefits from the new efficiencies

The benefits from the new system include reduced errors, labor and automatic QA inspection of the product.





CASE STUDY: Automated Order Processing at Liquor Distribution Center

Labels:

automated order processing


Class B Liquor Distributor located in Dallas, Texas uses fixed position scanners, vision systems and automatic label applicators to automatically process orders for their wholesale Liquor customers.


The Problem


Goody
Goody Liquor shipslLiquor, wine, beer and accessories from their Dallas, Texas Distribution Center to bars and restaurants in their geographical area. Prior to the installation of the current system, all order processing and tax stamp labeling was performed by hand requiring the full time attention of up to eight employees. According to Goody management, this process was both time consuming and prone to error and theft. These problems have virtually disappeared after the installation of the automated order processing system by Cornerstone Automation Systems Incorporated (CASI) that fully automated the order processing and tax stamp application  process.


integrated order processing
System
Overview



The
automatic order processing system from CASI utilizes table top chain conveyors, fixed position barcode scanners, vision systems, a label applicator, Rockwell PLC conveyor control and CASI’s SolidCount™ software to automate the process.


Hardware Description


  • Table Top
    Chain Conveyor
  • CASI-1050
    Control Console
  • Eight Data
    Logic Matrix 2000 Barcode Scanners
  • ST-600 Label
    Applicator
  • DVT Vision
    System
  • Keyence Color
    Vision System
  • Rockwell
    MicroLogix 1200 PLC


Software Description


  • SolidCount™
    Production Counting Module >
  • SolidComm™
    Legacy Host Interface
  • Custom
    PLC Controls


Releasing Orders


At the beginning of a run, the system uses the SolidComm™ communication module to get the order information from the Goody Goody Liquor Enterprise System. This data contains the expected UPC barcodes from the order. A custom modification to SolidCount™ enables conversion of the 6 digit UPC-E to their twelve digit uncompressed version.


in-bound barcode scanningIn-Bound Scan




After
the data for the order is downloaded, the system announces via pre recorded .wav file that it is ready to run. Bottles are placed on the conveyor and the array of eight Data Logic Matrix 2000 barcode scanners read the UPC barcode from all the positions the numerous manufacturers have placed them. The Matrix 2000 was chosen for this application due to its ability to decode low contrast barcodes at up to a 70 degree pitch or skew angle, as well as a 360 degree tilt.


automatic labeling
Automatic Tax Stamp Labeling


The Matrix 2000 was chosen for this application due to its ability to decode low contrast barcodes at up to a 70 degree pitch or
skew angle, as well as a 360 degree tilt.


OCR Capture of the Tax Stamp Number



As the stamp is fed onto the bottle, a DVT Vision System is used to capture the stamp number using the OCR tool. The tax stamp information is included in the customers shipping paperwork for his order providing proof each bottle has a tax stamp number. These OCR images can be saved as well to a hard drive.



 


vision systems


Label Placement Confirmation
Label Placement Confirmation



Once the stamp is on the bottle, it is seated with an air knife and a secondary wipe brush. Finally, a Keyence color vision system is used to positively verify that a properly seated tax stamp is on the bottle. Great care is made to ensure the tax stamp has been captured and is on the bottle, as missing stamps have caused
bars to lose their liquor licenses in the past.


 

Exception Processing

OCR Label Verification
Bottles that cannot be processed due to an unreadable barcode or failure of the OCR Capture or Label Verification are diverted to an exception lane.


The No Surprises Approach


Following
the standard CASI System Implementation Methodology, the critical parts of the system were modeled at the manufacturing center in Prosper Texas. Once all the components were working properly, the customer is invited to the manufacturing center to view the system.


Benefits from the New Efficiencies


Process Improvements have been dramatic producing a rapid payback on the original investment. Wrong items being shipped have disappeared along faster order processing. These gains allow Goody Goody Liquor to get
their orders out the door faster and more efficiently than before providing an advantage over their competition.

For more information: www.cornerstoneautosys.com