Automated Control System
Contents
1. oooooo 8 Figure 3 6 Conveyor after Stacker 2 unit 7 in fig 1 1 see 9 Figure Aa le HMISTU ouchsereens ener 13 Figure 4 2 Machine Struxure Pyramiden ee iae AA taa 14 Figure 4 3 Advantys FTB CANopen IP 67 monobloc VO splitter boxes 15 Figure 4 4 7 8 COME torsi eee elle 17 Figure 4 5 M12 5 pin CAN bus connector o ooocoW oW mmm 17 Figure 4 6 Circuit breaker and thermal overload relay ooooooWoW 18 Figure 7 1 Suggested sensor position 2 Henn a En 23 Figure 8 1 Picture of the final equipment setup see also tbl 8 1 o oooo 25 Figure 8 2 Limit switch with metal end plunger ooooWoomomoooo o WWW 27 Figure 8 3 Limit switch with steel roller ti man manga 27 Figure 84 Sensor test pla eel S 27 Figure 8 5 Lexium drive CAN settings ausanisssuertahnaskehmnhl ni 28 Figure 8 6 Splitter box CAN settings voii 28 Figure 8 7 CAN baud rate for project configured SoMachine sess 29 Figure 8 8 CAN node setting for PLC SoMachine esee 30 Figure 8 9 CAN node setting for component in project SoMachine 30 Figure 8 10 CANopen I O mapping for sensor variable eee 31 vil Figure 8 11 Sensor 0 sensor 2 and sensor 5 triggered ooooWoooooooo 31 Figure A 1 15 MC Power TK ede EN NBA RN 41 Fig re A 1 2 gt ConB2. The sensor test platform fig 8 4 was then connected to the PLC with a CAN bus cable and a temporary testing program was created on the SoMachine to test out if the communications were working between the splitter box and the PLC as intended at the same time the variable speed drive was disconnected from the CAN bus so that it would not interfere with the testing of new components Once the sensor test platform had been tested out it was disconnected and the Lexium integrated drives were wired up and connected to the CAN bus and tested in a similar fashion Figure 8 2 Limit switch with metal end plunger Figure 8 3 Limit switch with steel roller Figure 8 4 Sensor test platform 27 Once these different components had been tested out separately it was time to connect them serially line to line and get them to work together as a whole First attempts were not successful as the CAN bus system ran into errors on the PLC Connecting cables were checked for faulty wiring and the CAN bus node configurations were looked at problem was traced down to being incorrect CAN bus node manual configuration on components and setting of baud rate When that was done the components were able to communicate between each other using the CAN bus To configure the CAN node settings for the Lexium integrated drives the motor housing needs to be opened and the switches fig 8 5 and tbl 8 2 inside manually set to the desired settings For the
3. Automated Control System Selection Design and Programming of Automated Control System for a Conveyor Belt in Fishing Industry Gu mundur Arnar Gr tarsson Final thesis for B Sc degree Keilir Institute of Technology University of Iceland School of Engineering and Natural Sciences BER aem a AA Keilir FX gt nstitute of z y E y Technology gt UNIVERSITY OF ICELAND ESO 5330 Automated Control System Gu mundur Arnar Gr tarsson 24 ECTS thesis submitted in partial fulfillment of a Baccalaureus Scientiarum degree in Mechatronic Engineering Technology Advisors Sverrir Gu mundsson Urs la Ogn Gu nad ttir Keilir Institute of Technology University of Iceland School of Engineering and Natural Sciences Reykjanesb r May 2014 Automated Control System Selection design and programming of automated control system for a conveyor belt in fishing industry 24 ECTS thesis submitted in partial fulfillment of a Baccalaureus Scientiarum degree in Mechatronic Engineering Technology Copyright O 2014 Gu mundur Arnar Gr tarsson All rights reserved Keilir Institute of Technology School of Engineering and Natural Sciences University of Iceland Green sbraut 910 235 Reykjanesbeer S mi 578 4000 Bibliographic information Gu mundur Arnar Gr tarsson 2014 Automated Control System BSc thesis Keilir Institute of Technology University of Iceland pp 67 Printing H sk laprent Reykjanesbeer June 201
4. Stacker program patt 6 Ei 56 Figure A 2 15 gt Stacker program patt 6 ea inne en aan aa 56 Figure A 2 16 Testing function blocks for ILX drive eene 57 Figure A 2 17 Testing function blocks for ILX drive part 1 57 Figure A 2 18 Testing function blocks for ILX drive part 2 sees 58 Figure A 2 19 Testing function blocks for ILX drive part 3 58 ix List of Tables Table 1 1 Processing line Components urn 1 Table OL Protein a da Bana 21 Table 8 1 Components in fig 8 1 senin an Hee anna aan 26 Table 8 2 Lexium drive CAN settings iii anne aan 28 Table 8 3 Splitter box CAN settings suasa ant a 28 Table 8 4 CAN bus settings for project cy une 29 Table A 1 1 MC Power TEX parameters ae Reto lectus kg tedio 41 Table A 1 2 ConfigureIO ILX parameters una ee a niese 42 Table A 1 3 MC Readdigitalinput ILX parameters o ooooooooWomoWoW 42 Table A 1 4 MC Movevelocity ILX parameters ooooooo oo 43 Table A 1 5 MC Stop ILX parameters seen a 43 Table A 1 6 MC Setposition ILX parameters oooWooooomo oo oo W 44 Table A 1 7 MC Reset IL X parameter see ae 44 Table A 1 8 MC Moveabsolute ILX parameters oooooooWoooooW 45 Table A 1 9 MC Power ATV Parametros 46 Table A 1 10 Movevelocity ATV parameterS ooooooooWo oo W 46 Table A 1 11 MC Jog AT V parameters unserm are 47 Table
5. 2 Node ID x 10 8 800 Kbits s 3 Node ID x 1 9 1 Mbits s Figure 8 6 Splitter box CAN settings 28 Each component using the CAN bus needs to have a unique node number and the baud rate must be configured to be same on all components tbl 8 4 The CAN bus settings also need to be configured through the SoMachine software suit fig 8 7 8 9 Table 8 4 CAN bus settings for project 3 4 5 6 Altivar 312 Lexium ILA 1 Lexium ILA 2 FTBICN16CPO 127 TM238LFDC24DT 500 000 Home Properties Configuration Commissioning Report File Edit View Project Build Online Debug Watch Tools Window Help MISS Lu f FIB 1160 vx fig MyController TM238LFD C24DT va AI PLC Logic CANbus Application a Task Configuration 7 5 4 10 10 in HSC HSC FL PTO PWM PTO_PWM Serial Line1 g Modbus_Manager Modbus_Manager Serial Line2 Id tk Ea o gt 11 Ben MMO Library Manager 0 POU_Altivar PRG POU_FTBBlocks PRG POU LexiReset PRG Online Bus Access POU Lex2 PRG E Block SDO DTM and NMT access while application is running POU Lex2Keyrsla PRG POU Lex2Reset PRG POU Math PRG POU Samantekt PRG POU Stackeri PRG POU Stacker1 1 PRG 2 Symbol configuration Baudrate bits s C A N O PE A Network 5 EEE EEEEEE Sms embedded Functions a dachine Network Manager SoMachine Ne
6. 21 Needs analysis for Section 3 3 days Mon 7 4 14 Wed 9 4 14 22 2 Selecting sensors and motors position and type 4 days Thu 10 4 14 Tue 15 4 14 23 2 Connecting and wiring parts together 4 days Wed 16 4 14 Mon 21 4 14 24 x PLC Programming 5 days Tue 22 4 14 Mon 28 4 14 25 Work on final thesis 2 days Tue 29 4 14 Wed 30 4 14 26 Section 4 Stacker 2 11 days Thu 1 5 14 Thu 15 5 14 27 2 Needs analysis for Section 4 2 days Thu15 14 Fri2 514 28 Selecting sensors and motors position and type 2 days Mon 5 5 14 Tue 6 5 14 29 Connecting and wiring parts together 3 days Wed 7 5 14 Fri 9 5 14 30 PLC Programming 3 days Mon 12 5 14 Wed 14 5 14 31 pa Work on final thesis 1 day Thu 15 5 14 Thu 15 5 14 32 gt Section 5 Conveyor after Stacker 2 6 days Fri 16 5 14 Fri 23 5 14 33 x Needs analysis for Milestone 5 1 day Fri 16 5 14 Fri 16 5 14 34 Selecting sensors and motors position and type 1 day Mon 19 5 14 Mon 19 5 14 35 Connecting and wiring parts together 2 days Tue 20 5 14 Wed 21 5 14 36 2 PLC Programming 2 days Thu 22 5 14 Fri 23 5 14 37 Work on final thesis 1 day Mon 26 5 14 Mon 26 5 14 38 2 Other Work 5 days Fri 23 5 14 Thu 29 5 14 39 19 days Mon5 5 14 Thu 29 5 14 40 END 0 days Fri 30 5 14 Fri 30 5 14 30 Task Project Summary FAA Manual Task I Start only L Deadline Split Inactive Task Duration only Gu Finish only 3 Progress Milestone Inactive Milestone Manual Summary Rollup mn External Tasks Manual Progress Summary
7. ILAIB ILAIF ILAIR manual V200 logo EN pdf showAslIframe true amp fileName ILA1B ILAIF ILAIR manual V200 logo EN pdf amp reference 0198441113562 amp docT ype User guide 67
8. The electrical components handling the controlling of inputs and responses PLC motor drives splitter box and sensors are capable of delivering the functions set out by project The use of a touchscreen panel for project was not accomplished due to an error that could not be resolved within the limited time of the project 35 References 1 William Bolton Mechatronics 5th ed Pearson Education Limited 2011 2 Schneider Electronic 2013 July Magelis HMISTU655 855 User Manual Pdf Online http www schneider electric com download W W EN file 163031101 EIO0000000614 04 pdf show AsIframe true amp fileName E100000000614 04 pdf amp ref erence E100000000614 amp docType User guide 3 Schneider Electric 2014 May OEM machine programming software SoMachine A single software environment Online http www schneider electric com products ww en 5100 software 5140 pac plc programming software 2226 oem machine programming software somachine XTMC somachine amp XTCR 2 4 Schneider Electric 2009 September Advantys FTB CANopen IP67 Monobloc I O Splitter box User guide Pdf Online http www schneider electric com download W W EN file 27463201 1606218 02A55 pdf show AsIframe true amp fileName 1606218 02A55 pdf amp referenc e 1606218 02A55 amp docType User guide All the data and design about the mechanical side of the processing line was obtained from Gylfi P r Gu laugsson All i
9. has thus developed a protocol known as CAN or Controller Area Network The Can bus is now also used as a fieldbus in other automation systems Can is a multi master serial bus standard for connecting ECUs Each node in the system is able to both send and receive messages 1 ner CANopen is a higher level communication protocol that makes use of the CAN bus 10 Chapter 22 p 507 16 4 10 Supply to splitter box Supply input Supply output 7 8 male connector 7 8 female connector 1 Supply to splitter box and sensors 2 Supply to actuators Figure 4 4 7 8 connector Bus input Bus output Bus input Bus output CAN L CAN L M12 male connector M12 female connector Figure 4 5 M12 5 pin CAN bus connector Connectors and wiring diagrams 4 10 1 7 8 power supply to splitter box connector wiring Used to supply power to the I O splitter boxes fig 4 4 4 10 2 M12 5 pin CAN bus connector Used in the communications between I O splitter boxes and other nodes of the CAN bus system fig 4 5 See Appendix C IP 67 monobloc I O splitter boxes for fieldbuses Advantys FTB splitter boxes See Appendix C IP 67 monobloc I O splitter boxes for fieldbuses Advantys FTB splitter boxes 17 4 11 Safety measures As with any mechanical applications it is important to implement safety measures both to increase the safety of personnel that make use of the equipment and to prevent mechanical parts if someth
10. pulse signals servo motors respond to pulse driving signals by moving into a pre ordained motor position depending on the frequency of the pulse signal Servo motors offer the possibility of being easier to program for precise controlling Stepper motors have traditionally been more popular choice in precise machine controls like industrial robots but recent developments have lowered the price of servo motors and made them viable option in the industry 4 2 Motor drives Motor drives are used when there is need to affect the driven motor in a more specific manner than just on and off 1 e when there is need for a finesse in motor control for the application Motor drives are available in different types for the different variations of motors Variable speed drive for AC motors stepper motor drives for stepper motors and servo motor drives for servo motors 4 2 1Variable speed drive Used for the controlling the speed of motors 4 2 2Stepper motor drive Used for controlling a rotation speed of motor direction of rotation and programming of steps per rotation where available 4 2 3Servo motor drive Often already incorporated into the motor house itself continuously monitors position of motor and corrects if necessary Controls the position of motor in accordance to the frequency of the pulse signal received Chapter 9 5 pp 227 234 12 4 3 Power supply converter Systems using PLC motor drives and sensors often require the
11. system Parts of the automated control system need to communicate with each other so that the interaction between different machine components does not interfere with each other or disrupt the machine process This is done by using sensors or other monitoring equipment that conveys information on the machine status to the PLC which it then can react upon depending on its programming This can be implemented by direct cables from sensors to PLC using the I O connectors on the PLC or by using the serial bus interface and or CAN bus interface when available 4 9 11 0 direct connections Connection cables that lie directly from the monitoring equipment towards the PLC using the existing I O connectors that are available on the PLC or additional I O extension modules They are easy to setup and connect but have the disadvantage of requiring separate cable from each equipment to the PLC On larger automated machine installations with multiple monitoring equipment this can lead to overcrowding within the control cabinet from cables 4 9 2CAN bus A modern automobile may have as many as seventy electronic control units ECUs for various subsystems e g engine management systems anti lock brakes traction control active suspension airbags cruise control windows etc This could involve a lot of wiring However an alternative approach is use a common data bus with data transmitted along it and made available to all parts of the car Bosch
12. the final equipment setup see also tbl 8 1 25 Table 8 1 Components in fig 8 1 Touch panel screen HMISTU855 CAN bus connectors Logic controller TM238LFDC24DT Emergency stop button Lexium integrated drive ILA1F572PCA0 Circuit and Thermal overload breakers Sensor test platform Variable speed drive ATV312H037N4 CANopen junction box VW3CANTAP2 AC motor K21R71K4 The variable speed drive was used to test and simulate the parts of the project that would require the use of a conveyor belt Two Lexium integrated drives ILA1F572PCA0 were selected and used to test and simulate the Stacker 1 and 2 parts of the project one used for the X movement while the other would handle the Y movements When the two Lexium integrated drives were added it was decided to change out the existing power supply ABL8REM24030 on the conveyor belt system and replace it with a more powerful one ABL8RPS24100 ensuring that the Lexium drives would be able to draw enough current when needed Part of the project was also checking into if using VO splitter boxes would be a feasible solution The Advantys FTB CANopen IP67 Monobloc I O Splitter box FTBICN16CPO was selected because it makes use of the CANopen protocol The CAN bus was already being used for other electronic components of the project e g Altivar 312 variable speed drive Lexium integrated drives The CANopen junction box VW3CANTAP2 is used in this project so that the v
13. use of power supply converter modules If the main power source for the system is AC current it can affect the performance of computer driven equipment PLC The control circuit boards of motor drives are often powered by 24 volt DC Altivar 312 4 4 Programmable logic controller Programmable logic controllers are digital electronic devices which use programmable memory to store instructions to implement functions such as logic sequencing timing counting and arithmetic used to control machines and their processes They are made robust and often with specifics tasks in mind by tailoring them to meet certain operational needs By making them more specialized they run less risk of encountering errors while running under continuous operation This is often essential on industrial systems PLC run their programs continuously and update response and outputs based on the received input signals Hr 4 5 HMI interface The human machine interface the part of the machine that handles the interaction between the operator and the machine e g on off buttons computers touchscreens fig 4 1 2 dials emergency stop buttons and etc Every part that can affect the machine operation by usage of operator can be considered as part of the HMI interface on that machine gt ider mm Schne pone BE v B 5 Js 5 Figure 4 1 HMISTU touchscreens Chapter 21 p 491 2014 May Schneider Electric Online http ww
14. 1 4 Components description Descriptions of components that are usable in conveyor belt systems the functionality they offer and the differences between them 4 1 Electrical motors Even though there are different variations of electrical motors available they are based on the same principle i e to convert electrical energy into mechanical energy used to move mechanical parts Yet each type of them is differently suited for each task that is needed Below follows descriptions of types available 4 1 1 DC motors Brush and brushless DC motors can be split into two groups those that have brushes that are in direct contact with the moving parts of the motor and those that are brushless The ones with brushes are cheaper to manufacture but require more maintenance compared to the brushless counterparts DC motors are frequently used in appliances that run on low power or with battery driven source e g copy machines printer systems and remote controlled models nr 4 1 2 AC motors Single phase and polyphase AC motors can be divided into two groups single phase motors and polyphase Single phase motors can be found where there are low power requirements e g general household appliances or power tools like blenders or garage door openers Polyphase Multiphase motors are more likely to be used for higher power like in the industrial sector where more mechanical power is needed from the motors e g conveyor belt systems AC m
15. 4 Abstract A simulated model of an automated control system for a processing line under design for the fish processing company H teigur was implemented and programmed The processing line consists of conveyor belts and other moving parts The simulated model demonstrating different sections of the automated control system on the processing line was set up to see whether or not all the requirements proposed by the company H teigur could be accomplished The project was broken down into smaller sections since the real processing line has not yet been constructed and a smaller conveyor belt used for testing each individual part Utdr ttur Hermil kan af sj lfvirku styrikerfi fyrir vinnslul nu sem veri er ad hanna fyrir fiskverkunarfyrirt kid H teigur var framkv md og forrita Vinnslulfnan samanstendur af f rib ndum og rum hreyfanlegum hlutum Hermil kani s nir fram virkni hinna mismunandi tta af sj lfvirka st rikerfi vinnslul nunnar me a fyrir augun a athuga hvort h gt s a uppfylla allar kr fur sem lag ar eru fram af fyrirt kinu H teig Verkefninu var skipt upp minni hluta ar sem ekki var b i a sm a vinnslul nuna og pr fanir framv mdar litlu tilraunaf ribandi Table of Contents canitiem vii Last of Table nan binaan ANN BR uk xi ADOLECE xiii Deimitions lt a benene xiii Acknowl dg ments AM A IARE E RAT ER EUR XV AA O 1 2 Background General information ooooo
16. 4 1141 Eme rsency stop button AAA A ET 18 4 11 2 Circuit breakers Thermal overload breakers een 18 Un A Prosrammine arena rr A Project Components quac epe ar rtp Oi ak esel I Sensor position and motor types oooooooooooooooooooooooooooooooooooooooooooooooooooooood3 8 Results and discussion ooommmssssZo A SO ROO Red ercer dada Appendix A Programming coOde ooooooocoooooooooooooooooooooooooooooooooooooooooooooo 39 AL Function Block ea _Al 1 ILX Function Blocks oooo nana 41 A12 ATV Function Blocks nn a an 46 A1 3 Other Function Blocks rerrrrroonnonnnnrnrsrrsrrsernennnnrnrnenssnnnennnnnnrsensersennennnnrnrnene 48 AD Programs OU UST _A2 1 Lexium drives reset and set position sess 51 _A2 2 PR IO 53 _A2 3 Stacker PLOSTAM un ky A Ra kn i n 54 _A2 4 Testing function blocks for ILX drive esee 57 Appendix B Project plak ini o maba ea kak is Appendix C Datasheets web links ooooooooooooooocooooooooooooooooooooooooid vi List of figures Figure 1 1 Processing line see also tbl I Dasein ist 1 Figure 3 1 gt Processing line low Cdi ar en 5 Figure 3 2 Conveyor before Stacker I 42 ninia eed etna ha 5 Fipure 3 3 Stacker I aussen air ea 6 Figure 3 4 Conveyor with Scraper and Washer esee 7 Figure 3 5 Stacker 2 original design now been modified
17. A 1 12 MC Stop ATV DAA METER KA RI ER 48 Table A 1 15 RS parameters une eR DRUSI puan AN Sdn 48 Table A 1 14 GFU parameters ae ede da PERS nba 49 Table A 1 15 TON parameters avvek el 49 xi Abbreviations PLC Programmable Logic Controller AC Alternating Current DC Direct Current I O Input Output X movements Vertical movement Y movements Horizontal movement HMI Human Machine Interface CAN Controller Area Network ECU Electronic Control Units Definitions Stacker Mechanical part of the system that has X and Y movements it handles one tray at a time and either stacks it or takes it off a stack Scraper Stationary metallic plate with groves in it for trays to pass through while materials on the trays is pushed off as they pass it Washer Mechanical part of the system it works like a washing machine cleaning the trays passing through xiii Acknowledgements The design of the mechanical parts of the processing line was done by Gylfi P r Gu laugsson I want to thank Gylfi for his good advisement assistance and for always being ready to answer my questions when needed XV 1 Introduction The project is about selecting designing and programming an automated control system for a new processing line fig 1 1 under design for a fish processing company The processing line will take trays from a stack approximately eighteen trays in one stack one at a time scrape off the contents that are on it wash it and t
18. AN node setting for PLC SoMachine ZN Home Properties Configuration Commissioning Report File Edit View Project Build Online Debug Watch Tools Window Help Hg d EE LC Ls id MyController TM238LFDC240T Bl PLC Logic CANopen Remote Device PO Mapping Service Data Object CANopen 1 0 Mapping Status Information Application era Ben i Library Manager POU Altivar PRG POU FTBBlocks PRG POU LexiReset PRG POU Lex2 PRG POU_Lex2Keyrsla PRG POU_Lex2Reset PRG POU Math PRG POU Samantekt PRG POU Stackeri PRG POU_Stackerl_1 PRG ma Symbol configuration a Task Configuration S mast Embedded Functions 10 10 iD HSC HSC TLi PTO_PWM PTO_PWM Serial Line 1 fj Modbus Manager Modbus Manager 7 Serial Line2 CAN g CANopen_Optimized CANopen Optimized Altivar_312 Altivar312 CANopen I Enable Expert Settings IV Optional Device Enable Sync Producing EEEEEEEEEE 0 warning s 0 message s Lexium_ILA_1 Lexum ILA Lexium ILA 2 Lexium ILA J FT5_1CN16CPO FTB 1CN16CP0 Description Project Object Position Figure 8 9 CAN node setting for component in project SoMachine With the CAN node and baud rate setting configured both on components and in SoMachine the CANopen protocol is able to run without errors bringing all components used in the project online and t
19. Altivar 312 drive CAN bus settings are configured through the inbuilt HMI interface By selecting RDY CON ADCO the CAN node number can be set and through RDY CON BDCO the baud rate can be configured The Altivar 312 drive also has to have RDY CTL FR 1 NET set in order for it to accept remote control through the CAN bus The splitter box is configured through switches fig 8 6 and tbl 8 3 located on the front side Table 8 2 Lexium drive CAN settings S1 Hex kBaud 0 je s OFF 100 Switch settings Stand S2 1 2 S1 3 1 4 21 22 23 S24 1234 3 125 Address bit 6 5 4 3 2 1 0 ras OFF CC a a can Fieldbus address 127 debuly 1 1 1 1 1 1 1 Bt amp 5 4 7 1000 baud rate _ __ High address R Fleldbus address 25 example 0 0 1 1 0 0 1 S2 switch setting S4 Baud rate Kbaud S3 ON 1 50 ar tl OFF iic 1234 3 125 Bt3 210 4 250 res OFF Low address 5 500 interface mode ON A B OFF PULSE DIR 6 800 terminating resistor 7 1000 ON on res OFF Figure 8 5 Lexium drive CAN settings Table 8 3 Splitter box CAN settings Switch position Transmission speed DATA NODE ADDRESS x Z RATE X10 Xi 0 Automatic recognition VAS Nera 1 10 Kbits s Z gt 2 20 Kbits s 3 50 Kbits s 4 100 Kbits s 5 125 Kbits s Element Function 6 250 Kbits s 1 Sets the transmission speed 7 500 Kbits s
20. Axi Done Lexium_ILA 1 Axis Done Done01 Execute 65000 2000 Lexium ILA 2 A Lexium ILA 1 Done02 115000 2000 Lexium ILA 2 Lexium ILA 1 Done03 165000 2000 Figure A 2 12 Stacker program part 3 Position02LBlock MoveTray02Block MC MOVEABSOLUTE ILX Lexium ILA 2 Axis Done Lexium ILA 1 is z Done02 Execute 55000 Position 310000 2000 Velocity 2000 Position03LBlock MC MOVEABSOLUTE ILX MC MOVEABSOLUTE ILX 1 Lexium ILA 2 Axis Done Lexium ILA 1 Axis Done Done03 Execute Execute 105000 Position 310000 2000 Velocity 2000 Position04LBlock MC MOVEABSOLUTE ILX 1 Lexium ILA 2 Axis Done Lexium ILA 1 is Em Done04 Execute 155000 Position 310000 2000 Velocity 2000 Figure A 2 13 Stacker program part 4 55 Position05HBlock Lexium ILA 2 Done04 215000 2000 Position06HBlock MC MOVEABSOLUTE ILX Lexium ILA 2 Axis Done Done05 Execute 265000 2000 Figure A 2 14 Stacker program part 6 Position05LBlock MC MOVEABSOLUTE ILX Lexium ILA 2 Axis Done Execute 205000 Position 2000 Velocity Position06LBlock MC MOVEABSOLUTE ILX Lexium ILA 2 Axis Done Execute 255000 Position 2000 Velocity Figure A 2 15 Stacker program part 6 56 Lexium ILA 1 Lexium ILA 1 310000 2000 Lexium ILA 1 310000 2000 Lexium ILA 1 GetTray05Block MC MOVEABSOLUTE ILX i Done MC MOVEABSOLUTE ILX Axi Done MoveTray05Block Done05 Done06 A2 4 Testing fu
21. Guide Pdf Online http download schneider electric com files p Reference EIO0000000384 amp p EnDocType User9 620guide amp p File Id 455436187 amp p File Name EIO0000000384 06 pdf M238 Logic Controller Hardware Guide Schneider Electronic 2014 May M238 Logic Controller Hardware Guide Pdf Online http www schneider electric com download W W EN file 455436167 EIO0000000016 07 pdf show AsIframe true amp fileName E100000000016 07 pdf amp referen ce EIO0000000016 amp docType User guide Lexium ILx Field Bus Manual CANopen DS301 Schneider Electronic 2014 May Lexium ILx Field Bus Manual CANopen DS301 Pdf Online http download schneider electric com files p Reference ILx1F CANopenDS301 manual V201 EN amp p EnDocTy pe User 20guide amp p File Id 27549306 amp p File Name ILx1F CANopenDS301 manua I V201 EN pdf ILX Library Function blocks Software manual Schneider Electronic 2014 May ILX Library Function blocks Software manual Pdf Online http www schneider electric com download W W EN file 27639191 ILX FB Manual V209 EN pdf showAslIframe true amp fileName ILX FB Manual V209 EN pdf amp reference 0198441113886 EN amp docT ype User guide 66 ILA1B ILA1F ILA1R Lexium Integrated Drive Product manual Schneider Electronic 2014 May ILA1B ILA1F ILA1R Lexium Integrated Drive Product manual Pdf Online http www schneider electric com download W W EN file 27534461
22. ILX Done Busy 22 Error 227 Figure A 1 5 MC_Stop_ILX Table A 1 5 MC_Stop_ILX parameters FUNCTION_BLOCK MC_Stop_ILX Axis Axis Ref ILX VAR IN OUT axis structure Execute BOOL VAR INPUT rising edge starts execution Done BOOL VAR OUTPUT done without error Busy BOOL VAR OUTPUT busy Error BOOL VAR OUTPUT error occured 43 MC_SETPOSITION_ILX Axis Done Execute Busy Position Error Mode Figure A 1 6 MC_Setposition_ILX Table A 1 6 MC_Setposition_ILX parameters FUNCTION_BLOCK MC_SetPosition_ILX Axis Axis Ref ILX VAR IN OUT axis structure Execute BOOL VAR INPUT rising edge starts setting new position Position DINT VAR INPUT position Inc FALSE absolute position TRUE relative to actual motor position Done BOOL VAR OUTPUT set new position Busy BOOL VAR OUTPUT busy Error BOOL VAR OUTPUT error occured Mode BOOL VAR INPUT MC RESET ILX Done Busy Error Figure A 1 7 MC_Reset_ILX Table A 1 7 MC_Reset_ILX parameters FUNCTION_BLOCK MC_Reset_ILX Axis Axis Ref ILX VAR IN OUT axis structure Execute BOOL VAR INPUT rising edge starts execution Done BOOL VAR OUTPUT done without error Busy BOOL VAR OUTPUT busy Error BOOL VAR OUTPUT error occured 44 MC MOVEABSOLUTE ILX Axis Done Execute Busy Position CommandAborted Velocity Error Figure A 1 8 MC Moveabsolute ILX Table A 1 8 MC Moveabsolute ILX parameters FUNCTION BLOCK MC MoveAbsolute ILX Axis Axis Ref
23. ILX VAR IN OUT axis structure Execute BOOL VAR INPUT rising edge starts motion Position DINT VAR INPUT target position of movement Inc Velocity INT VAR INPUT target velocity of movement rpm Done BOOL VAR OUTPUT commanded position reached Busy BOOL VAR OUTPUT busy CommandAborted BOOL VAR OUTPUT FB was aborted by another command Error BOOL VAR OUTPUT error occured 45 A1 2 ATV Function Blocks MC POWER ATV Axis Status Enable Error Figure A 1 9 MC Power ATV Table A 1 9 MC Power ATV parameters FUNCTION BLOCK MC Power ATV Axis Axis Ref ATV VAR IN OUT axis structure Enable BOOL VAR INPUT FALSE switch off TRUE switch on State of power amplifier FALSE stas BOE sad switched off TRUE switched on Error BOOL VAR OUTPUT error occured MC MOVEVELOCITY ATV Axis InVelocity Execute Busy Velocity CommandAborted Error Figure A 1 10 Movevelocity ATV Table A 1 10 Movevelocity ATV parameters FUNCTION BLOCK MC MoveVelocity ATV Axis Axis Ref ATV VAR IN OUT axis structure Execute BOOL VAR INPUT rising edge starts motion target velocity of movement frequeny Velocity INT VAR INPUT 5000 5000 0 1 Hz InVelocity BOOL VAR OUTPUT commanded velocity reached Busy BOOL VAR OUTPUT busy 46 MC_JOG_ATV Done Busy Backward CommandAborted Velocity Error Figure A 1 11 MC Jog ATV Table A 1 11 MC_Jog_ATV parameters FUNCTION_BLOCK MC_Jog_ATV Axis Axis_Ref_ATV VAR_
24. IN_OUT axis structure start the jogged motion in Forward BOOL VAR_INPUT en i u positive direction clockwise start the jogged motion in Backward VAR_INPUT negative direction counterclockwise target velocity of movement frequeny 5000 5000 0 1 Hz Done VAR_OUTPUT done without error Busy VAR_OUTPUT busy FB was aborted by another command Error VAR_OUTPUT error occured Velocity VAR_INPUT CommandAborted VAR_OUTPUT 47 MC_STOP_ATV Done Busy Error Figure A 1 12 MC_Stop_ATV Table A 1 12 MC_Stop_ATV parameters Axis Axis_Ref_ATV VAR_IN_OUT axis structure Execute BOOL VAR_INPUT rising edge starts execution Done BOOL VAR_OUTPUT done without error Busy BOOL VAR_OUTPUT busy Error BOOL VAR_OUTPUT error occured A1 3 Other Function Blocks Figure A 1 13 RS Table A 1 13 RS parameters FUNCTION_BLOCK RS SET BOOL VAR_INPUT Input to set Q1 RESET1 BOOL VAR_INPUT Input to reset Q1 reset dominant Q1 BOOL VAR OUTPUT 48 Figure A 1 14 CTU Table A 1 14 CTU parameters FUNCTION BLOCK CTU VAR INPUT Count Up VAR INPUT Reset Counter to 0 VAR INPUT Counter Limit VAR OUTPUT Counter reached the Limit VAR OUTPUT Current Counter Value Figure A 1 15 TON Table A 1 15 TON parameters FUNCTION BLOCK TON starts timer with rising edge resets timer with falling edge VAR INPUT time to pass before Q is set VAR INPUT VAR OUTPUT gets TRUE delay time after a rising
25. Pt Inactive Summary Manual Summary pM External Milestone Page 1 61 Appendix C Datasheets web links Web links to user guides manuals datasheets and information concerning the components used in project Web links accessed and online in May 2014 SoMachine Programming Guide Schneider Electronic 2014 May SoMachine Programming Guide Pdf Online https stevenengineering com tech support PDFs 45MANUAL SOMACHINE PROGRAM pdf SoMachine Introduction Schneider Electronic 2014 May SoMachine Introduction Pdf Online http stevenengineering com tech support PDFs 45SOFTWARE SOMACHINE pdf Adventys FTB CANopen IP67 Monoblco I O Splitter box User guide Schneider Electronic 2014 May Adventys FTB CANopen IP67 Monoblco I O Splitter box User guide Pdf Online http www schneider electric com download W W EN file 27463201 1606218 02A55 pdf show AsIframe true amp fileName 1606218 02A55 pdf amp reference 16 06218 02A55 amp docType User guide IP 67 monobloc VO splitter boxes for fieldbuses Advantys FTB splitter boxes Schneider Electronic 2014 May IP 67 monobloc VO splitter boxesfor fieldbuses Advantys FTB splitter boxes Pdf Online http msavtomatika com ua sites default files doc schneider electric 2 promyshlennye ko ntrollery i paneli operatora promyshlennye kontrollery moduli udalennogo vvoda vyvoda advantys ftb advantys ftb katalog eng pdf ATV312 Programming manu
26. al Schneider Electronic 2014 May ATV312 Programming manual Pdf Online http www schneider electric com download W W EN file 27530066 ATV312 programming manual EN BBV46385 02 pdf showAsIframe true amp fileName ATV312 programming manual EN BBV46385 02 pdf amp reference BBV46385 amp docTy pe User guide ATV312 CANopen manual Schneider Electronic 2014 May ATV312 CANopen manual Pdf Online http www schneider electric com download W W EN file 27502303 ATV312 CANopen manual BBV52819 02 pdt showAslframe true fileName ATV31 2 CANopen manual BBV52819 02 pdf amp reference BBV52819 amp docT ype User guide 65 ATV312 Installation manual Schneider Electronic 2014 May ATV312 Installation manual Pdf Online http www schneider electric com download W W EN file 27501445 ATV312 Installation manual EN BBV46391_01 pdf showAslIframe true amp fileName A TV312 Installation manual EN BBV46391_01 pdf amp reference BBV46391 amp docType U ser guide Magelis HMISTU655 855 User Manual Schneider Electronic 2014 May Magelis HMISTU655 855 User Manual Pdf Online http www schneider electric com download W W EN file 163031101 E100000000614 04 pdf show AsIframe true amp fileName E100000000614 04 pdf amp referen ce E1000000006 14 amp docType User guide Modicon M238 Logic Controller Programming Guide Schneider Electronic 2014 May Modicon M238 Logic Controller Programming
27. ariable speed drive is able to connect to the CAN bus By setting the system up in such a way components could be connected in series and in case of malfunctions or replacements such a setup should make it easier in the long run to find and switch out faulty components First it was necessary to test and wire up existing components separately starting by testing if the conveyor belt was running as intended with the variable speed drive and if all the cables and connectors were wired correctly The original setup had a three phase power connector for powering the variable speed drive and the AC motor A power supply was also wired to that connector in order for the necessary 24 volt required to run the PLC and the HMI could be provided There were no readymade cables for the CAN bus ports of neither the I O splitter boxes nor the Lexium drives Therefore they had to be made on the spot with the necessary M12 5 pin connectors and cable in order for connecting those components to the CAN bus Where no connectors ends were available 7 8 connector was not available connections and cable were setup in a temporarily fashion see chapter 4 10 1 for wiring diagram so that working principles of the project could be proven 26 A clear plastic board was procured and drilled with holes so that 1t could be possible to fasten 8 sensors 4 with metal end plungers fig 8 2 4 with steel roller plunger fig 8 3 and a splitter box onto one platform
28. art Finish Dec 13 6Jan l4 20Jan 14 3Feb l4 17Feb 14 3Mar 14 17Mar 14 31 Mar 14 14Apr 14 28 Apr 14 12 May 14 26 May Mode leit siwisit MIF TisiWs TIMIF TIS WS TIMF TISWIS T MFITIsiwis T MIF T SIW S 1 START 0 days Thu2 1 14 Thu2 114 21 2 x B sc Final thesis 106 days Thu 2 1 14 Thu 29 5 14 3 2 Processing line 102days Thu 2 1 14 Fri 23 5 14 4 Project Preperations 22 days Thu 2 1 14 Fri 31 1 14 5 Gathering datasheets and user manuals about components 102 days Thu 2 1 14 Fri 23 5 14 6 Testing projects components 75 days Mon 3 2 14 Fri 16 5 14 7 2 Section 1 Conveyor before Stacker 1 20 days Mon 3 2 14 Fri 28 2 14 8 Needs analysis for Section I 3 days Mon 3 2 14 Wed 5 2 14 9 Selecting sensors and motors position and type 2 days Thu 6 2 14 Fri 7 2 14 EA Connecting and wiring parts together 6 days Mon 10 2 14 Mon 17 2 14 11 PLC Programming 5 days Tue 18 2 4 Mon 24 2 14 12 Work on final thesis 4 days Tue 25 2 14 Fri 28 2 14 13 Section 2 Stacker 1 12days Mon3 3 14 Tue 18 3 14 14 Needs analysis for Section 2 2 days Mon 3 3 14 Tue 4 3 14 15 Selecting sensors and motors position and type 3 days Wed 5 3 14 Fri 7 3 14 16 Connecting and wiring parts together 3 days Mon 10 3 14 Wed 12 3 14 17 PLC Programming 2 days Thu 13 3 14 Fri 14 3 14 18 Work on final thesis 2 days Mon 17 3 14 Tue 18 3 14 19 Break 13days Wed 19 3 14 Fri4 4 14 20 2 Section 3 Conveyor with Scraper and Washer 18 days Mon 7 4 14 Wed 30 4 14
29. bined with a variable speed drive making it possible for speed control on this Section Some materials that go through the processing line and are to be scraped off might offer different resistance wet material sticks more to trays compared to dry material making it a viable option to control the speed of the conveyor belt at this section by an operator Lowering the speed for the hard to scrape off material and raising it again for the easier material Section 4 Stacker 2 7 Limit switch When triggered informs the PLC that the stack of trays has reached its intended height 18 trays and can be moved onto Section 5 2 servo motors One for vertical movement of lowering the stack down and the other for horizontal movement of picking trays up from Section 3 and stacking them They offer position feedback at all times enabling movement control for correct positioning of trays 1 DC motor Small motor for controlling the holding unit which grabs the trays and holds them while they are transported from Section 3 onto a stack Section 5 Conveyor after Stacker 2 24 8 Limit switch When triggered informs the PLC that Section 5 is fully loaded and therefore Stacker 2 will need to go into waiting position until this Section has been unloaded and there is room again for new stacks 1 AC motor With this part there is no need for speed control and therefore a circuit breaker and a thermal overload relay will be enough for motor contr
30. control and therefore a circuit breaker and a thermal overload relay will be enough for motor control Section 2 Stacker 1 2 Limit switch When triggered informs the PLC that a stack of trays has been loaded into Stacker 1 ready to be unstacked upon Section 3 3 Limit switch When triggered informs the PLC that the top tray is in position for being picked up and moved onto Section 3 e 2 servo motors One for vertical movement of lifting the stack up and the other for horizontal movement of picking trays and placing them onto Section 3 They offer position feedback at all times enabling movement control for correct positioning of trays e 1 DC motor Small motor for controlling the holding unit which grabs the trays and holds them while they are transported from stack onto Section 3 Figure 7 1 Suggested sensor position 23 Section 3 Conveyor with Scraper and Washer 4 Limit switch When continuously triggered informs the PLC that Section 3 is fully loaded by trays Making it necessary for Stacker I to go into waiting position until this sensor goes off and there is room for another tray Limit switch Informs the PLC that a tray is about to pass into the Washer unit and that it should start up Can also be used as a counting trigger for number of trays going through the processing line Limit switch When triggered it informs the PLC that a tray is ready to be picked up by Stacker 2 1 AC motor AC motor com
31. ction needed counting or reacting when the sensors triggers 4 7 2 Optical sensors Optical sensors do not use physical contact mechanism to trigger the measurement they generate a beam of light which is either received by sensor on the opposite side or bounced back by reflective surface When that beam is broken the sensor triggers 4 7 3 Induction sensors Induction sensors are like mechanical sensor and optical sensors but do not use a physical contact mechanism or a beam of light to trigger They measure the change in inductance of the sensor coil when objects pass nearby their sensory surface Used for the detection of metallic objects 4 8 I O Splitter boxes Just like extension modules can be added to the PLC for increased I O operations there is also the option of using I O splitter boxes fig 4 3 which operate on the fieldbus Since they can make use of the fieldbus the CANopen protocol can be used in its setup of nodes and programming By use of I O splitter boxes a centralized automation system can be partly decentralized The I O splitter boxes can be connected to each other making cable connections more simplified and the replacements of parts easier on large automated systems instead of running cables from each component to the control cabinet where the PLC is located 4 Splitter boxes Figure 4 3 Advantys FTB CANopen IP 67 monobloc I O splitter boxes 15 4 9 Communication
32. e use of it for the processing line in handling the sensory inputs The timing of the X and Y movement for the stacker was measured The result when using the equipment at hand fig 8 1 and tbl 8 1 showed that the stacker unit would be capable of processing 18 trays in 2 minutes and 15 seconds This fulfills the requirement of processing 20 stacks of trays in 1 hour However the final result is different if the loading of new stacks into the stacker unit is taken into account and that the Y movement for the processing line is a longer distance than 600 mm the Lexium Linear motion used in project was only 600 mm long If the Y distance to travel would be increased to 1000 mm and the loading of a new stack of trays would take 15 seconds it was calculated that it would take the stacker unit 4 minutes to process one stack of 18 trays resulting in 80 minutes total to process 20 stacks of trays at current speed which was 20 minutes over the requirement for this section The Lexium integrated drives ILA1F572PCAO selected in this project were not able to deliver the necessary speed with the settings used Motors can be easily changed for more powerful and faster ones and incorporated into existing machine structure and programming as long as the same type of motor Servo AC DC with similar communication connections CAN are used in the recommended positions preferably motors from the same manufacturer as used in project Schneider Electric
33. edge at IN VAR OUTPUT elapsed time since rising edge at IN 49 A2 Programs A2 1 Lexium drives reset and set position Figure A 2 1 Lexium drives reset and set position Lex_PowerBlock POWER ILX Status IoConfig Globals Mapping FTB Skynjarar 128 Lexium ILA 1 Lex PowerOn Lex ConfigureInput00Block CONFIGUREIO ILX Lexium ILA 1 Axis Done Lex Input00ConfigureDone Lex PowerOn 0 0 CONFIGUREIO ILX Lexium ILA 1 i Done Lex InputOlConfigureDone Lex PowerOn 1 0 Configuration Figure A 2 2 Lexium drives reset and set position part 1 51 Lex ReadInput00Block MC READDIGITALINPUT ILX Lexium ILA 1 Valid Lex Input00Valid Lex PowerOn Value F Lex Input00Value 0 Inputs f Lex InputsValue MC READDIGITALINPUT ILX Lexium ILA 1 Valid Lex InputOlValid Lex PowerOn Value f Lex Input lValue 1 MC MOVEVELOCITY ILX Lexium ILA 1 axis InVelocity Lex PowerOn 200 Figure A 2 3 Lexium drives reset and set position part 2 Lex Input00StopBlock MC STOP ILX Lex InputsValue Lexium ILA 1 Axis Done Lex Input00StopDone 2 Execute Lex RSInput01Stop Lex Input01StopBlock RS MC STOP ILX Lex InputsValue SET o Lexium ILA 1 Axis Done Lex Input01CounterReachedLimit RESET1 Execute Figure A 2 4 Lexium drives reset and set position part 3 Lex InputOlCounter CTU Lex InputOlCounterReachedLimit CV F Lex CounterInput01Value Lex InputsValue 3 Lex Input0lStopDo
34. er Modbus Manager 7 78 Serial Line2 Create new variable y Mapto existing variable i SoMachine Network Manager SoMachine Networl CAN fj CANopen Optimized CANopen Optimized Altivar 312 Altivar312 Build 7 Oerror s Lexium ILA Er Project Object d FIB 1CN16CPO FTB 1CN16 C80 Figure 8 10 CANopen I O mapping for sensor variable Before sensor inputs can be used in any of the programs for this project they need to be located under the CANopen I O mapping fig 8 10 for the splitter box FTBICNI6CPO They are registered under a channel named Digital Input 8 Bits Pin2 Creating a new variable connected to the channel makes it accessible for use in programs created for this project The output of the channel is given as a byte 00000000 11111111 where each digit seat corresponds to a different sensor input 8 different connecter for sensor inputs on FTB1CN16CP0 but the signal is interpreted as a single number 0 255 As all the inputs are registered 1 on when sensors are not triggered the variable connected to the channel will return the value of 255 If sensor 0 sensor 2 and sensor 5 were to be triggered fig 8 11 the variable would return the value 218 11011010 This makes it possible to implement different responses into the programs of the project depending on the sensors triggered and the action required upon it 2 a 2 fz Q 6 Figure 8 11 Se
35. gurelQ IEX ua een eine un Sa De e ne tice 41 Figure A 1 3 MC Readdigitalinput IEX une ban ba 42 Figure AT MC Movevelocity ILX nennen Benannt 43 Figure A15 MC Stop EX se Bei BEA ee d eu ii 43 Figure A 1 6 MC Setposition UGX ivi age 44 Figure A 1 7 MC Reset IDX ini ads 44 Figure A 1 8 MC Moveabsol te TEA A ama saman 45 Figure ATS MC Power ATV 5 a aaa es 46 Figure A 1 10 Movevelootty UNT Viona ntuk naa man aa aman 46 Pigure AX Toe NIC Jos ATV An en An mm ana ha e ada Pee 47 Figure amp 1 12 MO SUD ATV na eit eu ea 48 Figure ALIS RS Pc EE 48 Figure A T 14 CTU sean ama ta ena BI an 49 Figure A 1 15 TON conil il ama 49 Figure A 2 1 Lexium drives reset and set position ooooo oo 51 Figure A 2 2 Lexium drives reset and set position part 1 oooooWooo 51 Figure A 2 3 Lexium drives reset and set position part 2 oooooWo 52 Figure A 2 4 Lexium drives reset and set position part 3 52 Figure A 2 5 Lexium drives reset and set position part 4 52 Figure A 2 6 Lexium drives reset and set position part 5 ooooo 53 Figure A 2 7 Lexium drives reset and set position part 6 53 Figure A 2 8 Altivar diversen a 53 PISA A PE 54 Figure A 2 10 Stacker program part Lag ak la dal 54 Figure A 2 11 Stacker program patt 2 Lorn rein 54 viii Ligure A 12 Stacker program patt avgasses ESN 55 Figure A 2 13 Stacker program patt A nen 55 Figure A 2 14
36. heir production line The machinery and capabilities of conveyors continuously evolves and hence there is always room for new improved solutions for production lines Every year there are some new innovations in the field of automated control systems Hence it is very progressive and offers many technical solutions for solving similar tasks The newest addition is probably the capability of accessing and controlling remotely through computers or smart phones The systems are able to monitor themselves and notify the personal supervising the equipment immediately 1f problem arises 2014 May The History Channel website Online http www history com this day in history fords assembly line starts rolling 5 2014 May Control Engineerinng Online http www controleng com single article machine control on the water via ipad 99508d0c64ddc 1495c5006e38337d5af html 3 Processing line functions The processing line is estimated to be over 10 meters and will have 8 sensors and 9 motors with room to add more if needed It needs to be able to control its tasks automatically The processing line was broken down into smaller sections fig 3 1 for this project Numbers in fig 3 1 correspond to the functions described in the different sections 3 1 Processing line breakdown DO amp 6 e pa 1 6 2 1 d N PG 4 i p d Section 3 Conveyor before scraper Section 1 Conve
37. hen restack them again The mechanical part of the processing line is designed by Gylfa P r Gu laugsson to accomplish the desired functionality set by the company H teigur The design of the automated control system of the processing line presented in this report is a collaborative effort between Gylfi H teigur and Keilir Institute of Technology Figure 1 1 Processing line see also tbl 1 1 Table 1 1 Processing line components Conveyor before Stacker 1 1 Loading Area 5 Washer 2 Sunc k Stacker 2 original design now been modified Conveyor after Stacker 2 3 80 x 80 tray 7 Butter Area 4 Scraper 8 Storage unit Part of the reason why H teigur is interested in testing out this idea rather than just using a robotic arm to handle the stacking of the trays is from their previous experience in using a robotic arm it was not performing up to their expectations of speed and needed too much maintenance Matth as Magnusson H teigur personal comment Jan 2014 Each stack loaded to the starting point of the processing line will consist of approximately eighteen 80 x 80 cm trays Each tray is expected to weight around eighteen kilograms when loaded with materials At the starting point there will be a loading area that can handle up to five stacks of trays it can be loaded occasionally every fifteen minutes This will save labor as the first stacker unit needs not to be constant
38. herefore capable of communicating and interacting with the PLC 30 A Home Properties Configuration Commissioning Report File Edit View Project Build Online Debug Watch Tools Window Help Hl l 5516 i EG OF 5 3 is MyController TM238LFD C24DT Fi Bl PLC Logic CANopen Remote Device PDO Mapping Service Data Object CANopen 1 0 Mapping status Information Application Channels d cv Variable Mapping Channel Address Type i MMO Library Manager T Write Outputs 1 to 8 QB24 USINT a POU_Altivar PRG Write Outputs 9 to 16 QB25 USINT a POU_FTBBlocks PRG ro Parameter Input DiagnosticatPin2 QB26 USINT a POU LexiReset PRG ro Parameter Input Output at Pin 4 QB27 USINT ei POU_Lex2 PRG ro Parameter Input Output at Pin 2 QB28 USINT a POU_Lex2Keyrsla PRG E Digital Ionut s Bits Pins IB28 USINT al POU Lex2Reset PRG EXP FIB Skynjarar m 1B29 USINT al POU Math PRG Peng 1B30 USINT al POU_Samantekt PRG Sensor short circuit IB31 USINT a POU_Stacker1 PRG 1 Actuator shutdown pin 4 961832 USINT il POU Stacker1 1 PRG Actuator shutdown pin 2 1B33 USINT a Symbol configuration EM Actuator mamina pin SLIR34 LISTNT Task Configuration 4 mast A Reset mapping Ma Embedded Functions Si 10 10 IEC Objects iD HSC HSC Variable Mapping Type FL PTO PWM PTO PWM FTB 1CN16CPO 9 CANRemoteDevice Serial Line1 Er Modbus Manag
39. ing goes wrong 4 11 1 Emergency stop button An emergency button intended to shut down all operations by cutting off power in some cases it will trigger the braking on motors so that they will stop quickly 4 11 2 Circuit breakers Thermal overload breakers Motors and other parts can quickly heat up if the system starts to draw to much current e g when it is running under more stress than intended Circuit breakers thermal overload relays fig 4 6 and temperature sensors located on motors can be installed to prevent equipment failure before it occurs Figure 4 6 Circuit breaker and thermal overload relay 18 5 Programming The programming for this project is all handled through the SoMachine software suite from Schneider Electric As stated in chapter 3 the project is split into smaller parts each part pertaining to a specific section fig 3 1 of the processing line By doing so the programming blocks for the processing line can be designed so that they are interchangeable with each other making it simpler to add or change parts of the project afterwards SoMachine offers the following six choices in programming language e Continuous Function Chart CFC e Function Block Diagram FBD e Instruction List IL e Ladder Logic Diagram LD e Sequential Function Chart SFC e Structured Text ST Programming was done in Function Block Diagram FBD which complies with the international standard for programmable
40. ker 2 that there are trays ready to be picked up and restacked The program for the conveyor belt that make use of relays for motor control is in waiting position till it gets a signal from the Stacker notifying that it is empty and requires a new stack of trays If the program detects from its sensor input that there is a stack waiting it will send it forward and stop once the Stacker unit tells it has received the stack and is now loaded again The program is reversed for the opposite effect Stacker 2 needs to be emptied and stacks are moved into buffer zone 32 For this project it had been planned to make use of a HMI touch panel screen but due to an error that could not be resolved within the limited time of the project 1t had to be disregarded 33 9 Conclusions The project was successful in demonstrating that electronic components selected for the project were capable of using the CANopen system as communication between themselves therefore using fewer cables towards the control cabinet with the PLC Also by using the same type of cable CAN cable between different component it should make 1t easier to replace or add components later on With the equipment setup fig 8 1 and tbl 8 1 it was possible to test out components and programs simulating the functions chapter 3 for the processing line fig 1 1 The testing and programming for the splitter box FTBICNI6CPO was successful showing that it was possible to mak
41. ly monitored from running empty The process line is required to be fast enough to manage up to 360 trays in one hour which amounts to about twenty stacks each hour At the end of the process line there will be a need for a buffer zone to temporally hold the stacks 1 e where stacks can wait until they are removed 2 Background General information Conveyor belts have been around for a long time First they were mainly used to transport coals and timber Henry Ford was the first person to utilize a conveyor belt as an assembly line for his Ford T model in the year 1913 The purpose of the automation implemented by a conveyor belt system is to reduce the need for labor and thereby lower production cost Since then the technology behind conveyor belts has come a long way especially after the advent of computerized control system even though the mechanical part of the conveyors have not changed much the control systems around them have taken great steps forward With automated control system conveyor belts are able to accomplish much more than just moving material between places The modern day sensors and mechanical controlling parts allows for the design of complex multitasking conveyor belt systems capable of multiple tasks in much shorter time and with less personal than during the early days The fishing industry makes use of processing lines for different tasks utilizing the benefits and efficiency that conveyor belts can bring to t
42. mages except for the photos taken personally by author were obtained from the home webpage of Schneider Electric http www schneider electric com or from datasheets and user manuals pertaining to components used in project which are published by Schneider Electric All images of function blocks and tables in Appendix A are obtained from SoMachine software suite programming library SoMachine is a software program made by Schneider Electric 37 Appendix A Programming code A1 Function Blocks A1 1 ILX Function Blocks MC POWER ILX Status Figure A 1 1 MC Power ILX Table A 1 1 MC Power ILX parameters FUNCTION BLOCK MC Power ILX Axis Axis Ref ILX VAR IN OUT axis structure Enable BOOL VAR INPUT FALSE switch off TRUE switch on TEP BOOL VAR OUTPUT State of power amplifier FALSE switched off E TRUE switched on Error BOOL VAR OUTPUT error occured CONFIGUREIO ILX Axis Done Execute IONumber Busy BETOE Configuration Figure A 1 2 ConfigurelO_ILX 41 Table A 1 2 ConfigurelO_ILX parameters FUNCTION BLOCK ConfigurelO ILX Axis Axis Ref ILX VAR IN OUT axis structure rising edge starts writing configuration Execute BOOL VAR INPUT E parameters number of IO to configure 0 100 1 101 2 102 32103 O input freely usable 1 LIMP input only configurable with 100 2 LIMN input only configurable with 101 3 STOP input 4 REF input 5 input programmable 128 outpu
43. nction blocks for ILX drive casi iryg lariacailalla zaz izm sza 2 zaz sseiriscmanis zazil las 21 zracccaCc cfiqormacic zaz2 elestetrgurml tigure zz Cocfiglrasctia Figure A 2 16 Testing function blocks for ILX drive Lex2 PowerBlock Lexium ILA 2 Lex2 EnablePower Lex2 ReadEnable MC MOVEVELOCITY ILX Lexium ILA 2 is InVelocit Y Lex2_InVel Lex2_MoveExecute Lex2_Vel MC READDIGITALINPUT ILX Lexium ILA 2 it Valid Lex2 SkynjariAvailable Lex2 AflesturEnable Value f Lex2 ValinnSkynjari Lex2 Skynjari Inputs Lex2 merki Figure A 2 17 Testing function blocks for ILX drive part 1 57 Lex2_SetPositionBlock MC SETPOSITION ILX Lexium ILA 2 Done Lex2 PositionDone Lex2 PositionEnable Busy Lex2 PositionBusy Lex2 SetPosition Lex2 SetMode MC READACTUALPOSITION ILX Lexium ILA 2 Axi Valid Lex2 PositionValid Lex2 ReadEnable Position Lex2 ActualPosition Lexium ILA 2 Lex2 AbsoluteStart Lex2 AbsoluteTarget Lex2 AbsoluteVelocity Lex2 MoveAbsoluteDone Lexium ILA 2 Lex2 ExecuteReset Lex2 ResetDone Figure A 2 18 Testing function blocks for ILX drive part 2 Lex2 ConfigureILXBlock Lexium ILA 2 Lex2 ExecuteConfigureation Lex2 SelectedInputToConfigure Lex2 ConfigureMode Configuration Lex2 ConfigurationDone Figure A 2 19 Testing function blocks for ILX drive part 3 58 Appendix B Project plan ID Task Task Name Duration St
44. ne Figure A 2 5 Lexium drives reset and set position part 4 32 Lex_SetPositionBlock MC SETPOSITION ILX Lexium ILA 1 i Done Lex SetPositionDone Lex Input01StopDone 0 Lex TimermMoveAbsolute 1000 Figure A 2 6 Lexium drives reset and set position part 5 Lex MoveAbsoluteRS Lex MoveAbsoluteBlock Q1 Lexium ILA 1 Lex_MoveAbsoluteDone Lex_MoveAbsoluteDone Figure A 2 7 Lexium drives reset and set position part 6 A2 2 Altivar drive IoConfig Globals Mapping FIB Skynjarar 128 Altivar 312 Alti PowerStatus Alti Move Alti InVel Alti Jog IoConfig Globals Mapping FIB Skynjarar Altivar 312 126 AltiVel2 IoConfig Globals Mapping FTB Skynjarar 125 stopBlock Altivar 312 stop Figure A 2 8 Altivar drive 53 A2 3 Stacker program me tig Gisbala mpptag syn dejaras a Figure A 2 9 Stacker program Position01HBlock GetTray0iBlock EQ MC_MOVEABSOLUTE_ILX IoConfig Globals Mapping FTB Skynjarar Lexium ILA 2 Axis Done 63 TE Execute 15000 Position 2000 Velocity Figure A 2 10 Stacker program part 1 Position01LBlock MoveTray01Block MC MOVEABSOLUTE ILX MC MOVEABSOLUTE ILX Lexium ILA 2 Axis Done Lexium ILA 1 Axis Done Done01 Execute Execute 5000 Position 310000 2000 Velocity 2000 Figure A 2 11 Stacker program part 2 54 Position02HBlock GetTray02Block MC MOVEABSOLUTE ILX MC MOVEABSOLUTE ILX Lexium ILA 2
45. ngth A longer Linear Motion rail would have been needed for the simulation of 18 trays therefore it was tested by running it 3 times on these settings for timing measurements The program for the Stacker see Appendix A chapter A2 3 starts by lifting the stack high enough for the Y movement unit to get under the topmost tray Once the Y movement unit is in position the stack is lowered leaving the top tray sitting on the Y movement unit it then moves with the tray towards its opposite end and deposits the tray there The same movement set repeats 6 times at which point the X movement arm will reach its top position At that point the whole program will return back to its starting positions and request a new stack of trays for it to unstack The program is reversed for the opposite effect stacking of trays back into stacks The program see Appendix A chapter A2 2 for Section 3 of the processing line see fig 3 1 makes use of the Altivar variable speed drive to handle control It is continuously on while Stacker 1 is putting trays on it moving trays through the Scraper and Washer towards Stacker 2 The speed settings for the conveyor are configurable through a physical turn dial located on the processing line making it easy to change speed if required It has triggering inputs from sensor to react upon if detects that the belt has no room for new trays It also triggers the sensor input to start the Washer After the Washer it notifies Stac
46. nsor 0 sensor 2 and sensor 5 triggered 31 Before any of the programs needed for the processing line were created it was necessary to create temporary programs see Appendix A chapter A2 4 to test out the program blocks available finding out their functions and limitations Testing out and locating the necessary function blocks for the final programs is time consuming but returns its investment in the long run When the Lexium integrated drives start up they do not know in which position they are so in order for making the best use of their precise position capabilities a program was made see Appendix A chapter A2 1 which makes the drive move till it hits the edge of 1ts movements in build sensor trigger a kill switch for the drive once it has located that position it resets itself and sets that position as 0 therefore making it possible for later programs to correctly position the moving arm of the Lexium integrated drive into preordained positions Thus it is possible to move in a set distance all the time just like the distance of moving one tray up would require Once the Lexium integrated drives are in position 0 they are ready for the next program The sensors on the splitter box trigger its activation The 600 mm distance of the Lexium Linear Motion rail was split up into 6 different positions for testing purpose the height of each tray was set at 100 mm made to simulate the off stacking of 6 trays in a whole run of its le
47. ol 8 Results and discussion It was decided to use mostly equipment from Schneider Electrics for this project The reason behind that was not only that they are an accomplished manufacturer of industrial solutions for automated control systems but also because Keilir Institute of Technology already had much of the electronic equipment needed to make the mini simulator of the belt conveyor fig 8 1 By using the equipment available on stock at Keilir Institute of Technology testing of different components for the project could be carried This made it possible to test and change out components as the project progressed A virtual machine software VMware workstation 10 was used for this project It was needed for running a virtual machine provided by Keilir Institute of Technology That virtual machine had Windows 7 operating system with the SoMachine software suite installed along with the CoDeSys gateway program These programs SoMachine and CodeSys were necessary for the configuration between electrical components and the programming part of this project Once the necessary programs had been procured and installed it was decided to use an existing conveyor belt system at school It already had a variable speed drive ATV312H037N4 PLC TM238LFDC24DT HMI touchscreen HMISTU855 and an AC motor On that setup additional components see chapter 6 for more detailed list would then be added later and tested Figure 8 1 Picture of
48. ooooooooooooocoooooooooooooooooooooooooooooooooooooo 3 3 Processing line functions ai era RERE NE 5 3 1 Processing Ime breakdown 2a 5 3 1 1 Short description of desired functionality eese 5 4 Components description siss sinnir a 11 4 l Electrical M TS see A NB 11 41 1 DC motors Brush and brushless a seen ia 11 4 1 2 AC motors Single phase and polyphase eee 11 4 1 3 Stepper Motos mios 12 4 1 4 Servo Mors ies er e OR EX EE NUES IS XANH STA E EELEE T EE adios 12 22 Morderen 12 42 1 Vanable Speed drive ii A is 12 42 2 Stepper motor drive isis os erre t te Een In aUe Seg Ra sevens anidan Ee esae e aere n 12 423 SEO MAO EVO se pereo iege i erd 12 45r Power supply converse 13 4 4 Programmable logic controller tried 13 45 Nel Na 13 4 6 SoMachine software suite nungen kit uo Pea a De peor eun ad 14 1 Sess 14 4 7 1 Mechanical sensors Limit switches eese 15 4 7 2 Optical SENSOTS beras ec ERO did m Bes uh 13 473 Induction Sensor make BN Na 15 4 8 JO Splitter DOXES e 15 NO RE 16 AOA VO direct connect idad 16 4 0 2 CAN DS anna o oec bg ica 16 4 10 Connectors and wiring diagrams eeonornronrvnrenvvnrerrvneerrnneerrnnerrrnssnrrvsenrrvsrnrssennrsser 17 4 10 1 7 8 power supply to splitter box connector wiring eene 17 4 10 2 M12 5 pin CAN bus connector o coooWooooomomm mann 17 AT Satety DEE i n 18
49. or more trays also needs to be able to let stacker 2 know if there are trays waiting to be stacked Figure 3 4 Conveyor with Scraper and Washer Section 4 Stacker 2 Stacker 2 fig 3 5 has X and Y movements It takes one tray at a time and restacks them on a conveyor belt Section 5 Once the stack reaches a height of eighteen trays the conveyor belt Section 5 is started Stacker 2 is emptied and can then begin stacking a new stack If the conveyor belt Section 5 does not have enough space for another stack Stacker 2 pauses until enough space becomes available 8 Detects if there are trays waiting on the conveyor before Stacker 2 and if so fetches them and stacks them 9 Needs to be able detect the height of the stack so that the lifting arm stacking arm can position itself correctly when stacking Also needs to be able to determine the height of stack so it knows to stop when a height of eighteen trays is reached 10 Starts the conveyor behind Section 5 Stacker 2 once stack reaches height of eighteen trays Figure 3 5 Stacker 2 original design now been modified Section 5 Conveyor after Stacker 2 The conveyor behind Stacker 2 fig 3 6 can hold up to five stacks of trays so that an employee only has to empty every fifteen minutes or so 11 Needs to be able to detect if there is room for more stacks on the belt or if it should pause Figure 3 6 Conveyor after Stacker 2 unit 7 in fig 1
50. otors can be further divided into two types i e induction motors and synchronous motors As with the DC brush motors the AC induction motors tend to be a lot cheaper to manufacture and hence much more popular than the synchronous motors AC induction motors have sometimes been referred to as the workhorse of the industry AC motors are generally cheaper than DC motors more robust less maintenance cost and more reliable They do however suffer from that controlling speed is often more complex than for with DC motors more expensive and involve variable speed drives for accomplishing that part 1 Chapter 9 5 pp 217 225 Chapter 9 6 pp 225 227 11 4 1 3Stepper motors Stepper motors are specialized versions of electrical motors providing more accurate control on the motors rotational circle each rotation 360 of the motor can be split up into equal steps angles where a pulse driven signal can make the motor move one step angle at a time Smaller DC motor often come with a set number of steps angles per rotation like 200 steps in one rotation while some AC motors with stepper motor drives can be programmed for different steps in one rotation depending on the level of control needed 1 4 1 4Servo motors Servo motors are similar to stepper motors i e they are used in applications where precision is necessary The difference between them is that while stepper motors are split into steps angles per rotation and driven by
51. programmers programming languages IEC 1131 3 19 6 Project components Compiled list of the electrical components and software used in the testing of this project tbl 6 1 wiring cables and small conveyor belt not included Table 6 1 Project components SES K21R71K4 ILA1F572PCAO PAS42BRM0600 ATV312H037N4 ABL8REM24030 ABL8RPS24100 TM238LFDC24DT SoMachine Suite v 3 1 10 1 VMWorkstation v 10 CoDeSys gateway program v 3 7CP21M12 ZCEO2 ZCEI1 HMISTU855 FTBICN16CPO VW3CANTAP2 LC1D09 GV2 P06 1 1 6A Rh ea m A A 00 AC motor 3Ph 400V 0 25kW Asynchron motor Lexium integrated drive AC synchronous servo motor Lexium Linear Motion 600 mm Variable speed drives for asynchronous motors Power supply 24V 3A Power supply 24V 10A Logic Controller Software Software Software Limit switch body Steel roller plunger Metal end plunger with nitrile boot Touch panel screen Advantys FTB CANopen IP67 Monobloc I O Splitter box CANopen junction box Thermal overload relay Circuit breaker 1 1 6A 21 7 Sensor position and motor types Suggested position for sensors fig 7 1 on the processing line and the selection of motors for each section See fig 3 1 in chapter 3 1 for section breakdown Section 1 Conveyor before Stacker 1 1 Limit switch When triggered informs the PLC that a stack of tray is waiting to be loaded into Stacker 1 e AC motor With this part there is no need for speed
52. raper and Washer Trays in this part fig 3 4 move forward towards the stationary Scraper which will remove the material on the trays off them into a storage unit to the side of the conveyor belt Once that has been done the tray is transported into a Washer unit which will rinse all material and dirt that is still stuck on the trays After the Washer there will be buffer zone for trays from which Stacker 2 picks them up and restacks them back into a stack of trays This part of the processing line has undergone modifications from the original drawing fig 3 4 a modification put forward by Gylfi and H teigur which are not represented there The planned design for this part is to have the starting area on a horizontal plane from there the conveyor belt will be on a rising incline ending in a 45 at the part where the Scraper is After the Scraper the conveyor belt will on a lowering incline ending again on a horizontal plane before the Washer unit It will no longer be three separate conveyor belts as represented in fig 3 4 but one whole unit 5 Detects when trays are loaded on it by stacker 1 and moves them forward towards the Scraper and Washer Needs to be able to stop Stacker 1 if belt is not moving and there is not enough room for a new tray 6 Stationary metal plate with grooves in it to let trays pass through but not the material on them 7 Needs to be able to let stacker 1 know if it is full or if there is room available f
53. t freely usable 129 index pulse output only configurable with 100 130 output programmable VAR OUTPUT IO configured without error VAR OUTPUT busy VAR OUTPUT error occured IONumber UINT VAR INPUT Configuration VAR INPUT MC READDIGITALINPUT ILX Input Valid Enable Busy InputNumber Error Value Inputs Figure A 1 3 MC Readdigitalinput ILX Table A 1 3 MC Readdigitalinput ILX parameters FUNCTION BLOCK MC ReadDigitallnput ILX Input Input Ref ILX VAR IN OUT axis structure TRUE returns the status of the inputs continously selects the input 100 0 101 1 102 2 103 3 Enable BOOL VAR_INPUT InputNumber INT VAR_INPUT Valid BOOL VAR_OUTPUT input signal is available Busy BOOL VAR_OUTPUT busy Error BOOL VAR_OUTPUT error occurred Value BOOL VAR_OUTPUT value of the selected input signal value of all inputs Inputs O 100 Inputs 3 103 Inputs WORD VAR_OUTPUT 42 MC MOVEVELOCITY ILX Axis InVelocity Execute Busy Velocity CommandAborted Error Figure A 1 4 MC Movevelocity ILX Table A 1 4 MC Movevelocity ILX parameters FUNCTION BLOCK MC MoveVelocity ILX Axis Axis Ref ILX VAR IN OUT axis structure Execute VAR INPUT rising edge starts motion Velocity VAR INPUT target velocity of the motion rpm InVelocity VAR OUTPUT commanded velocity reached Busy VAR OUTPUT busy CommandAborted VAR OUTPUT FB was aborted by another command Error VAR OUTPUT error occured MC STOP
54. tworl PCI pen Optimized CANopen Optimized Altivar 312 Altivar312 Lexium ILA 1 Lexum ILA Lexium ILA 2 Lexium ILA J FTB 1CN16CP0 FTB 1CN16CP0 Figure 8 7 CAN baud rate for project configured SoMachine 29 ZN File Edit View Project Build Online Debug Watch Tools Window Help iB 14 Ai G 5 3 13 OF gt ml ls 3 vx id MyController TM238LFD C247 2 S S PLC Logic Application aon CANopen MMO Library Manager POU_Altivar PRG Iv AutostertcANopenManage MW Pollingofoptionalslaves POU FTBBlocks PRG Check and fix POU LexiReset PRG M Start Slaves configuration POU_Lex2 PRG IT NMT StatAll if possible POU_Lex2Keyrsla PRG POU_Lex2Reset PRG Sync POU Math PRG I Enable Sync Producing POU_Samantekt PRG POU Stackeri PRG iain fizs 3 POU Stackeri 1 PRG Cyde Period us 50006 3 symbol configuration Task Configuration Window Length us o 3 5 Sms amp Embedded Functions IT Enable Sync Consuming 4 10 10 FR in HSC HSC Tli PTO PWM PTO_PWM IV Enable Heartbeat Producing Serial Line t Node ID 127 g Modbus_Manager Modbus_Manager i Producer Time ms r1 Serial Line2 ms 200 J Somachine Network Manager SoMachine Networ ovemosto O omessage s Lexum ILA 1 Lexium ILA Lexium ILA 2 Lexium ILA fj FTB_1CN16CPO FTB 1CN16CP0 Figure 8 8 C
55. w schneider electric com 13 4 6 SoMachine software suite SoMachine software suite is developed by Schneider Electrics for use with programming of PLC s manufactured by them SoMachine allows you to program and commission all the elements in Schneider s Electrics Flexible and Scalable Control platforms fig 4 2 By having all the different machine platforms united into one software package both programming and general overview of the program is made more visible and easier to manage The SoMachine program interface is also highly visual and intuitive 3 Figure 4 2 Machine Struxure pyramid 4 7 Sensors Sensors are essential parts of the automation solutions They generate the input signals which the PLC reacts upon The term sensor is used for an element which produces a signal relating to the quantity being measured ar The selection of sensors for automated applications depends on the parameters to be observed e g counting of objects volume of liquid in containers temperature color material type or other possible variations for measurement 2014 May Schneider Electric Online http www schneider electric com Chapter 2 p 29 14 4 7 1 Mechanical sensors Limit switches Sensors that trigger on contact They generate signals by passing current through them they are interpreted either as 1 and 0 on or off The PLC can then be programmed to respond to their signal depending on the fun
56. yor before stacker 1 Section 3 Scraper Section 2 Stacker 1 Section 3 Washer before stacker 2 Section 5 Conveyor after stacker 2 Section 4 Stacker 2 IR ONO Figure 3 1 Processing line flowchart 3 1 1 Short description of desired functionality Section 1 Conveyor before Stacker 1 The conveyor belt before Stacker 1 fig 3 2 can hold up to five stacks of trays so that an employee only has to reload new stacks every fifteen minutes or so 1 Is in waiting position while Stacker 1 is in use moves stacks one step forward when Stacker 1 signals it is empty Figure 3 2 Conveyor before Stacker 1 Section 2 Stacker 1 Stacker 1 fig 3 3 has X and Y movement It takes one tray at a time from the stack and puts it on the upper conveyor following Stacker 1 Height of stacks can be different when they are loaded into Stacker 1 2 Has to be able to identify if Stacker 1 is empty or not and if empty sends a signal to conveyor in front which responds by bringing in a new stack of trays 3 Has to be able to position trays into correct height so that the Y movement part can grab the trays one at a time and move them onto the upper conveyor belt 4 Puts the tray on the upper conveyor belt and needs to be able to identify 1f there is space available on it or if it has to stop because Section 3 is fully loaded by trays Figure 3 3 Stacker 1 Section 3 Conveyor with Sc
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