AUTOMATION CONTROL INSTITUTE INSTITUT FR AUTOMATISIERUNGS REGELUNGSTECHNIK Martin

AUTOMATION & CONTROL INSTITUTE INSTITUT FÜR AUTOMATISIERUNGS& REGELUNGSTECHNIK Martin Melik Merkumians 7 th 4 diac Users Workshop 4 diac in Teaching Lessonsfrom Lab Exercises and Student Projects

Content ¾ Student background at TU Wiens Electronics Master Programme „Energy and Automation Technology“ ¾ Lab course background ¾ Lab exercises ¾ Student project – transportation system ¾ Conclusion 06. 09. 2016 4 diac in Teaching 2

Student background ¾ Beginner level C skills (no object-orientation) ¾ Beginner level Java skills ¾ Basic Boolean algebra ¾ Basic understanding of finite-state machines (Mealy and Moore) ¾ Introduction to IEC 61131 language und execution model ¾ Introduction to IEC 61499 and its execution model 06. 09. 2016 4 diac in Teaching 3

Lab course background ¾ Master level course ¾ Focus on automation systems and IEC 61131 / IEC 61499 languages and concepts ¾ Approximately 120 -130 students in one semester ¾ Four parts / 4 h for each part + preparations at home ¾ Discrete manufacturing ¾ Batch process ¾ Industrial robot (6 axis articulated arm) ¾ Distributed control with IEC 61499 06. 09. 2016 4 diac in Teaching 4

Lab exercise – Mechanic Press Example ¾ 4 diac sample project ¾ Tasks ¾ Implement control with standard library function blocks only ¾ Implement a basic function block to control the mechanic press ¾ Add communication function block for control-to-simulation and control-to-GUI communication ¾ Pros ¾ ¾ ¾ Easy to set up Provided via 4 diac systems Distributed scenario (although running on one PC) Easy to debug for students Suitable for large lab classes (30+ students at once) ¾ Cons ¾ Simulation only / no hardware specific problems (e. g. Timings, real signal behavior) ¾ As nothing really happens/moves, students percieve the lab as rather boring 06. 09. 2016 4 diac in Teaching 5

Lab exercise – Measure and Sort NTC‘s Gantry robot Shaker Sorting station Measurement station 06. 09. 2016 4 diac in Teaching 6

Lab exercise – Measure and Sort NTC‘s 06. 09. 2016 4 diac in Teaching 7

Lab exercise – Measure and Sort NTC‘s ¾ Lab lecture notes ¾ Description of the plant ¾ Explanation of IEC 61499 and 4 diac ¾ 30 minute live demonstration of 4 diac (Flip-Flop tutorial) ¾ Basic FB creation and export ¾ Compile FORTE with new FB ¾ Test FB with monitoring ¾ Consultation with the lab lecture supervisor (me) and the responsible Student Assistant 06. 09. 2016 4 diac in Teaching 8

Lab exercise –Measurement Station Control ¾ Turn table in measurement position ¾ Close measurement clamps ¾ Start measurement and readout ¾ Open measurement clamps ¾ Turn table back ¾ Provide measurement to system 06. 09. 2016 4 diac in Teaching 9

Lab exercise –Overall control ¾ Shake NTC to takeout position ¾ Grab NTC with gantry robot ¾ Put NTC into measurement station ¾ Sort NTC depending on the measurement value 06. 09. 2016 4 diac in Teaching 10

Lessons learned from first year ¾ Short introduction (30 min) to 4 diac IDE/FORTE is not enough for most students to independently create 4 diac solutions ¾ Textual explanations of the desired processes are to inaccurate for preparations, even though we tried to be very accurate ¾ The event driven approach of IEC 61499 is hard to grasp for students at first ¾ Basic function block development with ECC and Algorithms is also not always clear to students ¾ FORTE compilation and FB creation should be all done in the same tool 06. 09. 2016 4 diac in Teaching 11

How to make things better ¾ Four tutorial videos how to install and use 4 diac ¾ Available at (German only) https: //www. youtube. com/channel/UCt 0 Ml. No 6 Y 7 d. XCZSDACXFi 1 g ¾ Test function blocks, which simulates the plant and gives advice if there any errors in the desired behavior ¾ Mandatory preparation of the control program ¾ No solution for combining FORTE compilation/FB creation steps 06. 09. 2016 4 diac in Teaching 12

How 4 diac got better through the use in lectures ¾ A lot of bug reports (120 testers per year ) ¾ ADS interface FBs for communication with Beckhoff hardware ¾ Added serial interface communication for Windows ¾ Added Raw. Data. Layer for communication ¾ Tutorial videos ¾ Input on how to enhance the ECC and Algorithms views in 4 diac-IDE 06. 09. 2016 4 diac in Teaching 13

Experiences of the second year ¾ Tutorial videos helped a lot! ¾ Setup steps for 4 diac IDE and FORTE are a bit to complicated for approximately 30% of students ¾ Visual Studio changed ¾ Too much tools (CMake, VS or Cygwin, and 4 diac IDE) ¾ Test FBs were very helpful, although they cannot cover all wrong behaviors ¾ 4 diac IDE has become much more stable 06. 09. 2016 4 diac in Teaching 14

Transportation system ¾ Platform Festo CPX-CEC ¾ Three different kinds of station types ¾ 2 -way junction ¾ 3 -way junction ¾ Handling station ¾ One program for each station ¾ Find shortest path between two stations ¾ Activate path in plant ¾ Communication via MQTT 06. 09. 2016 4 diac in Teaching 15

Testbed manager 06. 09. 2016 4 diac in Teaching 16

Feedback to 4 diac ¾ Again bug reports ¾ Most important - MQTT communication layer ¾ Able to run FORTE on Festo CPX-CEC (again) ¾ Can control I/Os and valve ports ¾ Unfortunately not open source 06. 09. 2016 4 diac in Teaching 17

Other systems controlled by 4 diac Nutcracker Platform: Festo CPX-CEC 06. 09. 2016 4 diac in Teaching 18

Other systems controlled by 4 diac Process plant Platform: Beckhoff CX 5010 06. 09. 2016 4 diac in Teaching 19

Conclusion ¾ 4 diac sample projects make it easy to ramp up a course or lab exercise to introduce IEC 61499, but lack reality ¾ Demonstration plants for exercises ¾ show the complexity and problems of real plants ¾ are more valued by students ¾ are a LOT more work to prepare and to use in exercises ¾ Helps to improve 4 diac ¾ Are incubators to create new 4 diac features 06. 09. 2016 4 diac in Teaching 20