Ciros Advanced Mechatronics Manual 1

CIROS
Advanced
Mechatronics
Manual
572761 EN
01/2010
Order No.: 572761
Status: 01/2010
Authors: Christine Lffler
Graphics: Doris Schwarzenberger
Layout: 01/2010, Beatrice Huber, Julia Saenscheidt
Festo Didactic GmbH & Co. KG, 73770 Denkendorf, 2006-2010

Internet: www.festo-didactic.com
E-Mail: did@de.festo.com
The copying, distribution and utilisation of this document as well as the

communication of its contents to others without express authorisation
is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved, in particular the right to carry out patent, utility
model or ornamental design registration.
2
Contents
1. What will you learn from the manual? ____________________ 5
2. This is how you install CIROS Advanced Mechatronics _____ 8

2.1 User-specific installation of default sample systems
and S7 programs used ________________________________ 8
3. The CIROS Advanced Mechatronics system _____________ 11

3.1 Summary of CIROS Advanced Mechatronics _____________ 11
3.2 A distributed system in CIROS Advanced Mechatronics____ 15
3.3 Communication in distributed systems __________________ 17
3.4 The preassembled station models in
CIROS Advanced Mechatronics _______________________ 19
3.5 Controlling a station with internal PLC __________________ 27
3.6 Controlling a station with external PLC __________________ 28
3.7 Functions for setting faults in a system__________________ 30
3.8 Functions for analysing a system ______________________ 31
3.9 Directory and file structure of
CIROS Advanced Mechatronics _______________________ 33
4. Main control functions of CIROS Advanced Mechatronics __ 38

4.1 Creating a new MPS Standard system
from preassembled station models _____________________ 38
4.2 Creating an MPS 500-FMS system
from preassembled station models _____________________ 58
4.3 Modifying an existing system _________________________ 78
4.4 Creating and monitoring communications links
in a system ________________________________________ 93
4.5 Simulating a system ________________________________ 120
4.6 Operating and monitoring a system ___________________ 124
4.7 Changing the view of a system _______________________ 145
4.8 The Inputs and Outputs windows _____________________ 149
4.9 The Manual Operation window _______________________ 157
4.10 Controlling a system using the internal S7 PLC __________ 183
4.11 Controlling a system station using
the external Soft PLC S7-PLCSIM ______________________ 199
Festo Didactic GmbH & Co. KG 572761 3

Contents
4.12 Controlling a station of the system using

the external Soft PLC CoDeSys SP PLCWinNT ____________ 215
4.13 Controlling a station of the system using an external PLC __ 241
4.14 Setting faults in a system ____________________________ 259
4.15 Eliminating faults in a system ________________________ 267
4.16 Logging error elimination ____________________________ 272
5. These training contents can be taught using

CIROS Advanced Mechatronics ______________________ 274
5.1 Training contents and training aims ___________________ 274
5.2 Target group ______________________________________ 277
5.3 Prior knowledge ___________________________________ 277
5.4 Example: Allocation of training aims to syllabi ___________ 278
5.5 The training concept of CIROS Advanced Mechatronics ___ 284
5.6 Training scenarios for CIROS Advanced Mechatronics ____ 286
6. This is how you create and operate a distributed

system in CIROS Advanced Mechatronics ______________ 289
6.1 Training aims _____________________________________ 289
6.2 Support via CIROS Advanced Mechatronics ____________ 290
6.3 Example: Configuration of a distributed system from
MPS Standard stations and simulating production ______ 290
7. This is how you analyse information flow in

a distributed system________________________________ 318
7.1 Training aims _____________________________________ 319
7.2 Methods _________________________________________ 319
7.3 Support via CIROS Advanced Mechatronics ____________ 321
7.4 Example: Analysing information flow in
a distributed MPS Standard system __________________ 321
4 Festo Didactic GmbH & Co. KG 572761

1. What will you learn from the manual?
What is CIROS Advanced CIROS Advanced Mechatronics is an application from the CIROS
Mechatronics? Automation Suite.
CIROS Advanced Mechatronics is a PC based graphic 3D simulation
system for distributed automation systems. These systems consist of
different, internetworked, intelligent stations. The distributed systems
represent automation processes of varying complexity.
In the documentation and software, these systems are also referred to
as process models or workcells.
CIROS Advanced Mechatronics is a tool whereby you

define an automation process and configure the corresponding
system for the predefined stations,
familiarise yourself with the mode of operation of a system,
familiarise yourself with and plan the communication between the
networked stations of a distributed system,
practise PLC programming and testing of PLC programs with the help
of systems,
carry out systematic fault finding on a system.
The individual contents can be extended in complexity depending on

the trainees prior knowledge.
The simulated systems are also available as actual systems. With these
you can successfully apply and consolidate the knowledge gained on
the virtual automation systems using actual systems.
In addition to the ready-made process models, CIROS Advanced
Mechatronics also offers you the option of simulating process models of
your own design. You can create and modify process models using
CIROS Professional, which is a further application available from the
CIROS Automation Suite.

Target group The manual is intended for

Trainers and teachers
The manual provides them with ideas and suggestions as to how
CIROS Advanced Mechatronics can be used in lessons and in
vocations and further training.
Trainees and students
For whom the information and instructions on how to operate
CIROS Advanced Mechatronics are of particular interest.
Structure of the manual The manual is divided into the following subject areas:
Chapter 2 contains information and instructions regarding the
installation and licencing of CIROS Advanced Mechatronics.
Chapters 3 and 4 describe the system and the main operational
functions of CIROS Advanced Mechatronics.
Chapter 5 deals with the didactic aspects and lists the training
contents taught with CIROS Advanced Mechatronics. It further
represents the training concept and the resulting possibilities for
use in lessons.
Chapters 6 and 7 describe actual problems in relation to the training
contents, methodological procedures towards solutions and
implementation in CIROS Advanced Mechatronics.
Conventions Specific notation is used for texts and key combinations and key
sequences to help you find information more easily.
Notation Meaning
Bold This format is used for command names, menu names, dialog box names,
directory names and command options.
Key1+key2 A plus symbol (+) between the key names means that the keys quoted must
be pressed simultaneously.
Key1key2 A minus symbol (-) between the key names means that the keys quoted must
be pressed in sequence.

Additional support Further descriptions and support is available via the online Help. The
online Help consists of:
CIROS Help for operation and
CIROS Advanced Mechatronics Assistant.
CIROS Help contains detailed information regarding the functions and

operation of CIROS Advanced Mechatronics.
CIROS Help is a component part of the CIROS Automation Suite and
describes the functionality of various, different CIROS applications.
The functional scope of CIROS Help is therefore greater than that
required for CIROS Advanced Mechatronics.
The menu of the online Help provides functions that you are already
familiar with from a standard Internet browser. These include: Next and
Back, Select Home Page, Print Selected Topics, Show/Hide the
Navigation bar or Set Options for Internet Connection.
Moreover, via extension registers such as Content, Search, Favourites,
you also have the option of conveniently navigating through the
information in CIROS Advanced Mechatronics Help.
The CIROS Advanced Mechatronics Assistant provides detailed

functional descriptions and technical documentation regarding the
individual stations. A sample PLC program is included for each station.
The PLC program is created in STEP 7.
Moverover, CIROS Advanced Mechatronics Assistant offers you direct
access to some ready made sample systems and prepared exercises.
A Getting Started section is also integrated for a quick introduction to
CIROS Advanced Mechatronics.
An Adobe Acrobat Reader must be installed on your PC to enable you to

view PDF documents. The Adobe Acrobat Reader program is available
free of charge and you can download this from the Internet address
www.adobe.de.
Our telephone hotline is available at any time, should you have any
queries during the installation or operation of CIROS Advanced
Mechatronics.

2. This is how you install CIROS Advanced
Mechatronics
To install CIROS Advanced Mechatronics you will need the CIROS

Automation Suite DVD-ROM, where all the software packages of the
CIROS Automation Suite are ready for installation. It also includes the
manuals in the form of PDF documents for the individual software
packages.
On completion of the installation, you will need to execute the licencing.
As soon as this is successfully completed you can start CIROS
Advanced Mechatronics.
For further information regarding system requirements, installation and

licencing, please refer to the enclosed instructions.
2.1 To be able to simulate a modelled system, a PLC program must be

User-specific installation available for each station of the system in order to control the operation
of default sample systems of the station. Each station is equipped with an internal PLC to execute
and S7 programs used PLC programs. A S7 simulator is used as internal PLC.
If you are working with the default settings of CIROS Advanced

Mechatronics, the prepared sample PLC program is automatically
downloaded to the internal PLC and executed once simulation is
started. This enables you to simulate the sample systems provided and
any newly created system straight away and without errors.
If you wish to modify one or several sample PLC programs, then the PLC
programs must be installed in an additional subdirectory specified by
you, where you can effect your changes. You can then download the
modified programs to the appropriate station of your system and
execute these. You can of course also download the modified PLC
programs to an external PLC, in which case the respective station of the
system using an external PLC.

2. This is how you install CIROS Advanced Mechatronics
By using this procedure, the default PLC programs used

by CIROS Advanced Mechatronics remain unchanged and can be
downloaded again to the internal PLC of a station.
CIROS Advanced Mechatronics supports you in the user-specific

installation of the sample systems and S7 programms. To do so, open
up CIROS Advanced Mechatronics Assistant.
CIROS Advanced Mechatronics differentiates between reference

models und user models.
Reference models are sample systems which are filed in the
program directory of CIROS Advanced Mechatronics and are write
protected. The model and associated PLC programs cannot be
modified. This ensures that the process model can be opened and
correctly simulated at any time.

2. This is how you install CIROS Advanced Mechatronics
User models, if created and opened with the help of CIROS

Advanced Mechatronics Assistant, are filed as standard in your
personal folder under own files\CIROS\CIROS Advanced
Mechatronics Samples. These are not write protected and you
therefore can for example modify the appropriate PLC programs and
replace these with your own. The program directory with the user
models represents your individual working environment for CIROS
You can also copy the user models into a folder other than into the
standard preset folder. You will find the information for this in CIROS
Advanced Mechatronics Assistant.
For the user modells created with the help of CIROS Advanced
Mechatronics Assistant the following directory structure is created:

3. The CIROS Advanced Mechatronics system
The following form part of CIROS Advanced Mechatronics:

The simulation software CIROS Advanced Mechatronics,
The communication software EzOPC,
The online CIROS Advanced Mechatronics Help,
An online CIROS Advanced Mechatronics Assistant,
An Online Help for EzOPC,
A PDF document with information regarding the licencing and
installation of a licence server,
A manual in the form of a PDF document for the operation of CIROS
3.1 CIROS Advanced Mechatronics is a PC-based graphic 3D simulation

Summary of CIROS system which serves as an introduction to automation systems with
Advanced Mechatronics distributed intelligence.
CIROS Advanced Mechatronics enables you to create, program and
simulate distributed systems of varying complexity.
A distributed system consists of one or several stations. One station is

characterised by the fact that it independently executes specific
machine functions; it is therefore an autonomous system part with its
own PLC program.

CIROS Assistant CIROS Help
System consisting of station models
Library Station 1 Station 2 Station 2 ...

with Control
station functions
Internal Internal Internal
models S7 PLC S7 PLC S7 PLC
OPC-Client
EzOPC (OPC-Server)
Easy S7-PLCSIM CoDeSys PLCWinNT

Port
External
PLC
Component parts of CIROS Advanced Mechatronics
The following is required in order to simulate the operation of a

distributed system:
A graphic process model of the distributed system,
A PLC program and PLC for each station, which autonomously
controls the operation of the station and, if required, exchanges
information with other stations,
A simulator that simulates the behaviour of the system. This
simulation ensures for example that cylinders move and sensors are
actuated.

Each station is stored in a library together with a sample PLC program.

The PLC program defines a possible sequence of the station. You can of
course create new PLC programs, which generate a different process
sequence.
If a system is now modelled from the prepared stations, the

corresponding PLC program is automatically downloaded to the internal
PLC of the station. A SIMATIC S7 simulator is used as internal PLC,
which executes the PLC program once simulation is started.
In order to ensure that the stations of the system interact correctly, they
need to exchange information.
The default communication links used between the stations are
established automatically.
This facility enables you to simulate the operation of a system

immediately after modelling.
The advantage of this is that you can familiarise yourself with, operate
and observe the process without having to create the PLC programs for
the individual stations beforehand.
In the next step you can establish or change the communication links
yourself and make the necessary adjustments in the PLC programs.
One particular additional function provided by CIROS Advanced

Mechatronics is the possibility of fault simulation, whereby it is possibly
to set typical faults in the system. Possible causes of malfunction are for
example a mechanically misadjusted sensor, a cable break or failure of
a complete. The cause of the fault must be found by means of
systematic fault finding and eliminated.

The monitoring and analysing of processes and the elimination of faults

is a focal point of CIROS Advanced Mechatronics.
A further focal point is the creation of your own PLC programs for
individual stations. These PLC programs are downloaded to an external
PLC and CIROS Advanced Mechatronics exchanges the input/output
signals with the external PLC via the OPC interface.
The following are possible as external PLC:

Any actual PLC,
The Soft-PLC SIMATIC S7-PLCSIM,
The soft PLC CoDeSys PLCWinNT.
CIROS Advanced Mechatronics requires the software program EzOPC

for the link to an external PLC. The OPC server EzOPC communicates
with any PLC via the EasyPort interface.
Note In addition to the ready-made process models, CIROS Advanced

Mechatronics also offers you the option of using process models of your
own design. You can create and modify process models using CIROS
Professional, which is a further application available from the CIROS
Automation Suite.

3.2 Systems can be created from one or several stations. Each station
A distributed system in represents an "intelligent unit", which independently executes specific
CIROS Advanced machine functions.
Mechatronics An "intelligent unit" consists of a station, a predefined sequence with
predefined communication interface, a PLC program, an internal PLC
and an optional robot program. The predefined sequence of the PLC
controlled stations can of course be modified by the user.
All stations are prepared for your use:

Processing station,
Fluidic Muscle Press station,
Handling station
Automated warehouse station,
Storing station,
Pick & Place station,
Testing station,
Buffer station,
Quality assurance station,
Robot station,
Robot assembly station,
Sorting station,
Separating station,
Pallet transport system with 6 working positions so-called docking
positions - for MPS 500-FMS stations,
Distributing station.
Two types of system can be created from the stations listed above:
MPS Standard systems,
MPS 500-FMS systems.

Example of an MPS Standard system
Example of an MPS 500-FMS system

The stations are available from two libraries:

The MPS stations library,
the MPS 500-FMS library.
Due to the technological functions of the individual stations and if using

the prepared PLC programs, only specific combinations are permissible
when modelling a system.
Note A system can also be configured of only one station. This enables you to
teach all the training contents for which only one individual station is
required.
MPS systems perform different production processes:

MPS Standard systems perform the assembly of measuring
instruments and short-stroke cylinders.
MPS 500-FMS systems include stock administration and assembly
of short-stroke cylinders.
3.3 To ensure the correct sequence of the production process, the

Communication in "intelligent units" of the system must exchange information. In other
distributed systems words, they need to communicate with one another. In MPS systems
these are the individual stations. How and with whom the stations
communicate depends on their position in the material flow.
In the case of MPS Standard systems a station usually communicates

with the preceding and successor station. In the standard version, one
bit is exchanged in each case. Information is exchanged via optical
sensors. This type of coupling of stations is referred to as StationLink.
Through-beam senor emitters and receivers are used as StationLink
sensors.

With MPS 500-FMS systems, each station forming part of the

transport system communicates with the transport system. Only in this
way does the transport system know which stations are involved in the
production process and in which working position these are.
If two stations are in use at one working position, such as the
distributing and testing stations at the position for incoming goods, an
information exchange therefore also takes place between these two
stations.
All stations of an MPS 500-FMS system communicate via the coupling

of PLC inputs and outputs. This type of communication is known as I/O
connection. In addition, the stations located at the working positions of
the transport system use the optical sensors for information exchange.
The part of communication conducted via I/O connection can be

graphically projected and modified.
If changes are made in the communication link, you need to make sure
that the PLC programs of the respective stations make available the
communication information accordingly and conversely also evaluate it
again.
Projection and representation of communication links

3.4 The station models are realistic replications of existing stations.

The preassembled station Apart from the graphic representation, each station model comes with a
models in CIROS sample PLC program and, if required, a robot program.
Advanced Mechatronics
Station model Description
Processing station
This model is a simulation of the MPS processing station

from Festo Didactic. On this station workpieces are to be
tested, processed and transferred to the neighbouring
station.
Fluidic Muscle Press station
This model is a simulation of the Fluidic Muscle Press

station from Festo Didactic. On this station workpiece
inserts are to be pressed into the workpiece housings and
the finished workpiece transported to the transfer position.

Handling station
This model is a simulation of the MPS handling station

removed from a mounting and, depending on the result of
the material testing, deposited on a slide. The workpieces
can also be passed on to a neighbouring station.
Automated warehouse station
This model is a simulation of the automated warehouse

station of Festo Didactic. On this station workpiece are to
be stocked up and taken out.

Storing station
This model is a simulation of the storing station of Festo

Didactic. Depending on the position of the station within
the material flow, workpieces are to be either stocked up or
taken out.
Pick & Place station
This model is a simulation of the Pick & Place station of

Festo Didactic. On this station workpieces are to be placed
onto workpiece housings and the complete workpiece is
transported to the transfer station.

Testing station
This model is a simulation of the MPS testing station from

Festo Didactic. On this station the material condition of the
workpieces is to be established and the workpiece height
checked. Depending on the test result, the workpiece is to
be ejected or transferred to the neighbouring station.
Buffer station
This model is a simulation of the MPS testing station from

Festo Didactic. On this station workpieces are to be
transported, buffered and separated.

Quality assurance station
This model is a simulation of the MPS quality assurance

station from Festo Didactic. On this station the shape
tolerance of workpieces is to be tested.
Robot station
This model is a simulation of the MPS robot station from

Festo Didactic. On this station workpieces are to be sorted
according to colour and the correct alignment of
workpieces monitored. Depending on the result,
workpieces are sorted into different magazines and passed
on to the neighbouring station.

Robot assembly station
This model is a simulation of the MPS robot assembly

station from Festo Didactic. On this station a model
cylinder is to be assembled from a basic body.
Sorting station
This model is a simulation of the MPS sorting station from

Festo Didactic. On this station workpieces are to be sorted
according to material and colour.

Transport system station
This model is a simulation of the MPS transport system

station from Festo Didactic. On this station workpieces are
to be transported to the individual station of an MPS 500-
FMS system.
Separating station
This model is a simulation of the MPS separating station

from Festo Didactic. On this station the material flow is
split The basic body for the cylinder is transferred to
conveyor 1 and the housing for the measuring instrument
is transported to conveyor 2 and transferred to the
neighbouring station.

Distributing station
This model is a simulation of the MPS distributing station

separated and passed on to the neighbouring station.

3.5 Each station in CIROS Advanced Mechatronics has an integrated

Controlling a station with SIMATIC S7 simulator as internal PLC. The S7 simulator can execute
internal PLC LDR, FCH, STL and GRAPH programs created in STEP 7.
When you start the simulation of a system, the internal PLC executes the
sample PLC program forming part of the station. This enables you to
familiarise yourself with the running of a system immediately after
modelling in the simulation.
Detailed information regarding the functional scope of the internal PLC
can be found on the CIROS online Help.

3.6 If you are creating and testing your own PLC programs for the individual
Controlling a station with stations of a system, we recommend that you download the programs
external PLC to an external PLC and execute them from this. The advantage of this is
that you can use the PLC and the programming system of your choice.
Also, the testing and diagnostic functions provided by the programming
system are thereby available to you in the PLC program for fault finding.
This includes the status display of PLC input/outputs and variables, the
online display of the PLC program and also the read-out of machine
statuses.
You do not need any additional hardware components if you use the
Soft-PLC S7-PLCSIM or CoDeSys SP PLCWinNT as external PLC.
Station of a system PLC programming system STEP7
Soft PLC S7 PLCSIM
Information exchange with configuration using the external Soft-PLC S7-PLCSIM

If you use a hardware PLC as external PLC, you will need EasyPort and
the data cable for the exchange of input/output signals. EasyPort
transmits the input/output signals of the PLC to the OPC server EzOPC
via the serial or USB interface of the PC. The OPC server passes on the
data to the selected station during the system simulation and,
conversely, the statuses of the sensors and actuators of the
corresponding station are communicated to the external PLC.
EasyPort
PLC
Information exchange with configuration using an external hardware PLC

3.7 The dialog to set faults in a system is password protected. Access to

Functions for setting this dialog is available solely to trainers and teachers.
faults in a system A list of typical faults is available for each station. Select one or several
faults from this list.
The task for trainees is to identify and describe the fault occurring
during system operation and to subsequently determine the cause of
the fault. The trainees enter the suspected fault in the dialog box for
error elimination.
If the fault has been correctly identified, the system then operates
correctly. The entries in the dialog box for fault elimination are logged
and can be viewed by trainers and teachers.

3.8 With CIROS Advanced Mechatronics, you have numerous options to

Functions for analysing a monitor and analyse the operation of a system.
system
As soon as system simulation is active and the PLC programs of the
individual stations control the operation of the system, you can operate
and visually monitor the process.
The process is controlled via the pushbuttons and switches of the
individual control consoles.

LEDs on the sensors and valves indicate the electrical status of the
process components.
LEDs on the PLC inputs and outputs on the control console indicate
the status of the communication realised via these inputs and
outputs.
If compressed air is applied to a cylinder connection, then the
connection is highlighted in blue. The compressed air tubing itself is
not simulated.
The statuses of the PLC inputs/outputs are shown in separate
windows.
A Manual Operation window provides an overview of all process
statuses and process activities.
In the Manual Operation window you can also display the
communication links between two selected stations.
If you want to execute the sequence step-by-step, then use the Manual
Operation window as tool for control. By setting stops, you can stop the
process at defined points.
If a PLC program is not active during system simulation, you can use the
Manual Operation window to activate individual process activities,
whereby you can for example control the movement of a cylinder or the
switching on or off of an electric motor.

3.9 Here you obtain information about the directory and file structure of
Directory and file CIROS Advanced Mechatronics.
structure of CIROS This information is useful if,
Advanced Mechatronics You want to make available the model of a system to other users,
You want to modify the sample PLC programs for the individual
stations of a system.
Directory structure The following directory structure is created if you install CIROS
following the installation Advanced Mechatronics with the default settings offered.
of CIROS Advanced
Mechatronics

Programs
. . . ciros advanced mechatronics.en
bin
FD_PLC_ADV
...
...
MB4
S7
313c___1 PLC programs for
MPS 500-FMS stations
FMS50__1 PLC program for

MPS 500-FMS
transport system
MPSC_V22 PLC programs for
MPS Standard stations
Store PLC program for

MPS 500-FMS automated
warehouse station
Samples
...
Models
MPS500-FMS51 MPS 501-FMS system
Model Workcell for
MPS 501-MPS system
Programs PLC program for
MPS 501-FMS system
MPS500-FMS57 MPS 507-FMS system
MPS System MPS Standard system
with separating with separating station
Multi-Bit-IO
MPS VE-PR MPS Standard system with
distributing and testing stations
(multi bit communication)
Model
Programs
One-Bit-IO
MPS VE-PR MPS Standard system with
distributing and testing stations
(one bit communication)
MPS VE-PR-SO MPS Standard system with
distributing, testing and
sorting stations
(one bit communication)
Programs PLC and robot programs for

all MPS stations

The S7 project with the sample PLC programs for the individual stations
is stored in the directory S7. These original PLC programs must not be
modified! The same applies to S7 programs and process models in the
folder Samples.
If you want to modify one or several of the sample PLC programs or of

the process models, you need to copy the directory Samples in another
subdirectory defined by you, where you carry out your modifications.
You can then download the modified programs to the internal PLC of the
appropriate station and execute it.
With this procedure, the default PLC programs used by CIROS

Advanced Mechatronics remain unchanged and can be reloaded again
to the internal PLC of a station at any time.
CIROS Advanced Mechatronics Assistant helps you copy models and

example PLC programs. For easy identification, copied models are called
user models and the original models are called reference models.
Project structure for the The example of a system is used to show what files form part of a
modelled systems modelled system and what information is stored in these files. A system
is also known as a process model or workcell. All files which are part of
the graphic representation of the system are filed in the user-defined
subdirectory.
If additional CIROS Advanced Mechatronics systems are also stored in

the subdirectory viewed, then files with corresponding names are also
available for these systems. Moreover the list of bmp files is more
extensive. It is however difficult to allocate bmp files to individual
systems.

File Description
Example.mod Process model of a system named Example.
Example.ini Initialisation of the process model:

The file contains all user-specific settings for the process model such as
window configuration, fault settings, etc.
It also contains a reference to the location and name of PLC programs to be
executed after simulation of the internal PLCs of the stations is started.
Example.prot Log of fault localisation:

The file is read in teacher mode and displayed in the fault log window.
Example.htm Exporting of fault log:

Modifications in the fault log are automatically exported into these files.
Example.xls
These files can then for example be viewed via Microsoft Internet Explorer or
Example.txt Microsoft Excel.
Example.mcf Fault settings:

This file contains all the settings regarding the activation, start, duration and
type of a fault.
If this file exists in the process model directory, it overwrites the settings in
the ini-file. If it does not exist, then the fault settings filed in the ini-file are
used.
*.bmp Various bitmap files required for the graphic display of the system. The
bitmap files required are dependent on which stations are used in the
system.
Files for a process model
A system also includes PLC programs, which are executed either via an
internal or external PLC. These PLC programs control the running of
individual system stations. The file *.ini includes a reference to the
memory location of the PLC programs.

You need to keep this in mind if you want to copy a system you have
modelled yourself to another PC and simulate from there.
If you want to copy the process model of a system, the best way to
proceed is as follows:
Select all the files forming part of the system. These are all the files,
which have the name of the respective system and all the bitmap
files.
Copy the selected file to a subdirectory of the desired PC. The
subdirectory on the target PC must have the same name and the
same path as on your PC.
If the station is operated using the sample PLC programs, make sure
that the sample PLC programs on the new PC are stored in the same
path as on your PC. If this is not the case, start CIROS Advanced
Mechatronics on the new PC and download the copied process
model. Then download the desired PLC program from the relevant
directory on the new PC to the internal PLC of the individual system
stations. By downloading the PLC programs, the reference in the ini
file to the memory location of the PLC programs is automatically
corrected. The system can now be simulated.
If one or several stations of the system are controlled via your own
created PLC programs, then these programs must also be available
on the new PC. The PLC program must be downloaded to the
corresponding system stations on the new PC.

4. Main control functions of CIROS Advanced
Mechatronics
This chapter describes the main control functions of CIROS Advanced

Mechatronics. Various options to activate commands are available via
MS Windows programs. In this description, commands are triggered via
entries in the menu bar. You can and should of course use the symbols
bar, appropriate key combinations or the context-sensitive menu with
the right mouse button.
Detailed information regarding the use of all the options of CIROS

Advanced Mechatronics can be found in the online Help for this
software package.
Note To enable you to create a wide range of different system, the library has
been extended with the addition of new station models. The new
standards regarding circuit diagram design are taken into consideration
in the PLC programs and circuit diagrams. "Old" and "new" standards
differ with regard to the designations of valve coils, pushbuttons and
switches as well as indicator lights.
4.1 The stations models for the configuration of a system are available in
Creating a new MPS two libraries:
Standard system from MPS stations library,
preassembled station MPS 500-FMS library.
models
If you want to model a new MPS Standard system, then use the models
from the MPS stations library.
This library contains the station models for the following:

Processing station,
Fluidic Muscle Press station,
Handling station,
Storing station,
Pick & Place station,
Testing station,
Buffer station,
Robot station,

4. Main control functions of CIROS Advanced Mechatronics

Sorting station,
Separating station
Distributing station.
Station models for an MPS Standard system are arranged directly next
to one another.
The alignment and connection of models is effected in a simple way via
specified coupling points on the models. The automatic alignment
ensures that the StationLink sensors of neighbouring stations are also
correctly positioned. The StationLink sensors are optical sensors which
transmit the communication signal.
Note A system can also be configured of just one station, whereby you can
teach all the training contents in CIROS Advanced Mechatronics for
which only a single station is required.
Due to the technological functions of the individual stations, only

certain combinations are permissible when modelling a system. The
possible combinations, i.e. subsequent stations, are indicated with grey
shading.

This is how you Distributint adjusted
for successor station

Handling adjusted
Handling adjusted
combine your
MPS Standard
for termination
Distributing
stations
Pick & Place

Processing
for Testing
Standard
Testing
Buffer
Distributing Standard
Distributing adjusted
for testing
Testing
Processing
Handling adjusted for

successor station

termination
Buffer
Pick & Place
Fluidic Muscle Press
Separating
Storing Stock up
Storing Take out
Robot
Robot assembly
Sorting
Permissible station combinations for MPS Standard systems

This is how you

combine your
Storing Stock up
Storing Take out

MPS Standard
Robot assembly
stations
Separating
Sorting
Robot
Distributing Standard
Distributing adjusted
for testing
Testing
Processing

successor station

termination
Buffer
Pick & Place
Separating
Storing Stock up
Storing Take out
Robot
Robot assembly
Sorting
Permisible station combinations for MPS Standard systems

The distributing, handling and storing stations are available in two

variants. Depending on the combinations in which the stations are used,
individual sensors and stops are differently positioned and adjusted.
The distributing station can deposit workpieces at two different transfer

positions. The sensors which determine and detect the swivel angle on
the transfer module must be correspondingly set. The lower transfer
position is required for the testing station; all other stations operate
using the higher transfer position. The distributing station variants are
therefore correspondingly designated with distributing station
adjusted for testing station and distributing station standard design.
The handling station can deposit workpieces at two different positions:

Internally on the station or externally at the transfer position of the
sucessor station. The sensor which determines the transfer position of
the axis must be correspondingly positioned. If the handling station
forms the end of a system, then the workpieces are deposited on the
station itself. In this case you will require the variant handling station
adjusted for termination. If there is a successor station, the workpieces
are deposited on the transfer position of the successor station. This
variant of the handling station is referred to as handling station
adjusted for successor station.
The robot station can also deposit workpieces at two different

positions: Internally on the station or externally on the transfer position
of the successor station. The robot program automatically detects
whether or not a neighbouring station follows and adapts the robot
movement accordingly. This station can therefore both be used in the
middle of or as a last station in a production system.
Two sequences are available for the storing station: The station can
stock up or take our workpieces. Each sequence is realised via a
separate PLC program. If the station is at the beginning of the material
flow it thus forms the first station of a system consequently
workpieces are taken out. In this case you will require the variant
Storing Station Take out. If the storing station forms the end of a
system, then you use the variant Storing Station Stock up.

The operation of the system with the prepared PLC programs can only
be simulated fault-free if a system is correctly assembled.
The modelling of an MPS Standard system is explained with the help of

an example.
A combination consisting of the distributing, testing and sorting
stations is to be configured.
This is how you create an MPS Standard system
An MPS Standard system consisting of the distributing, testing and

sorting stations is to be created.
1. Start CIROS Advanced Mechatronics.
When CIROS Advanced Mechatronics is started, both the activity
window and the help window are opened.

Note In CIROS Advanced Mechatronics Assistant open the folder which

contains the required process model. This is where a functional
description and technical documentation regarding the model are
available.
In addition, you can download a few prepared sample systems directly
from the Assistant.
If you do not require the information of the Assistant when starting
CIROS Advanced Mechatronics, deactivate the entry Open
Automatically of the assistant in the Help menu.
2. Activate the command New in the File menu. Click onto MPS
System.
The window Create MPS System is now displayed.
3. Select a directory as memory location for the new system and enter
the file name. Under file type, select CIROS Workcells (*.mod).
Then click onto Save.

4. The model of a blank system is displayed. By creating a new system,

a number of the following settings are automatically effected in
CIROS Advanced Mechatronics:
The change into Edit Mode is effected,
A table with the possible workpieces is made available,
The view selected is Top View,
The Model Libraries window is open.
5. A brief description of the model selected is displayed when you click

onto Details in the Model Libraries window.
Detailed information regarding the models in the library is available
on the online Help in the chapter CIROS Advanced Mechatronics.
You start Help by activating the command Examples and models of
CIROS Advanced Mechatronics in the menu Help.

6. First add the distributing station model. The distributing station is

available in two variants. Since the testing station follows the
distributing station in the sample system, select the entry
Distributing Station Adjusted for Testing Station under MPS
Stations. A preview then displays the model. Now click onto the Add
button.
Alternatively, add a model by double clicking on the relevant model
corresponding model entry.
The system now consists of the distributing station adjusted for
testing station model. The distributing station is shown in green as
it is still highlighted. Moreover the distributing station is connected
automatically to the workpiece table, since it has been added as the
first station.

7. Click outside of the station to cancel the highlighting.

A coupling point is shown on side of the station, which indicates that
the distributing station can be connected to a further station at this
point.

8. If the representation of the station is too small, you can change this
using the commands in the View menu.

9. Make sure that the Edit Mode is selected. You can establish this by
the check mark next to the Edit Mode command in the Modeling
menu. Now add the testing station as an additional station.

10. All stations are added at the same position in the workspace. Move
the newly added testing station, by highlighting the testing station
and, by holding down the left mouse button, moving the mouse
pointer to the desired position.
11. The two models are next to one another, but are not yet connected.
In order to ensure that the operating and transfer points coincide
during the production run of the system, the station models must be
appropriately aligned and connected.

12. Now align the testing station model with the distributing station
model.
To do so, click onto the lower, grey shaded coupling point of the
testing station. Hold down the left mouse button and drag the
coupling point to the coupling point of the distributing station.
The testing station is now connected to the distributing station.

13. Add the sorting station as the last station. This station is also shown
at the predefined position in the activity window.

14. Click onto the newly added, still highlighted station and move it up
next to the testing station.

15. Connect the sorting station model with the upper free coupling
point of the testing station model.
To do so, click onto the grey shaded coupling point of the sorting
station. Hold down the left mouse button and drag the coupling
point to the free coupling point of the testing station.
The highlighting of the model is cancelled as soon as you click
outside of the station model.
16. The system is configured. The communication links, realised via

optical sensors, are automatically established via the correct
positioning and connecting of the stations.

Exit the edit mode as soon as your system is configured. Change to the
view mode to obtain a realistic 3D representation of the system.
Note It is not absolutely necessary to connect the workpiece table to a

station. You can position the workpiece table at any point within the
workspace.

This is how you change to the view mode
1. Deactivate the Edit Mode command in the Modeling menu by

clicking onto the Edit Mode command. The check mark next to the
Edit Mode is removed.
2. A 3D representation of your system is now displayed. A top view is
also shown.
3. Close the Model Libraries window and select a perspective view of

the system.

4. To obtain a perspective view of the 3D model, select for example the

command Standard Views/Default Settings in the View menu. With
the commands under View you can move, rotate or zoom to obtain
an appropriate view of your system.
The system is correctly configured and connected. You can now

simulate system production right away.

Note Once you have created or modified a system, a Save prompt will be
displayed when you close the process model.
If you want to save the changes, answer the prompt with Yes or answer
with No if you want to discard the changes.
4.2 The station models to configure a system are available in two libraries:
Creating an MPS 500- MPS Stations library,
FMS system from MPS 500-FMS library.
preassembled station
models If you want to model an MPS 500-FMS system, then use the station
models from the MPS 500-FMS library.
The possible configuration levels of an MPS 500-FMS system are

based on the full configuration of the MPS 500-FMS system, where all
six working positions on the transport system are occupied by a station
or a combination of stations.

Product output Stock Assembly
S HL RM
Small parts store
Presorting
HH
P H VI
V B
Product input Processing Quality assurance
V: Distributing station P: Testing station HL: Automated warehouse station

H: Handling station B: Processing station HH: Handling station
VI: Quality assurance station RM: Robot assembly station S: Sorting station
Full configuration of an MPS 500-FMS system
The following form part of a full configuration of an MPS 500-FMS

system:
Pallet transport system station with 6 working positions for MPS
500-FMS stations,
Station combination consisting of distributing and testing stations,
Station combination consisting of handling and processing stations,
Quality assurance station,


Automated warehouse station,
Station combination consisting of handling and sorting stations.
The following rules apply to create MPS 500-FMS systems in different

configuration stages:
Only the listed six stations or station combinations can be
positioned on the transport system.
For each station or station combination, there is exactly one
permissible working position in the transport system. The position
can be seen from the full configuration of an MPS 500-FMS system.
Individual "positions" on the conveyor can remain unoccupied,
whereby individual stations or station combinations and their
associated production steps are omitted.
Example: The smallest MPS 500-FMS system consists of the
transport system station, the distributing and testing stations
combination for product input and the handling and processing
stations combination for product output.
The positioning and alignment of the models is effected simply via the
specified coupling points on the models.
In the case of MPS 500-FMS systems, the station models are aligned
with the transport system model and connected to it. The connection or
coupling points correspond to the stopper positions of the transport
system. As a result of establishing the connections, the default
communication links used are also simultaneously established.
The operation of the system can only be simulated error-free if a system

is correctly configured.
The modelling of an MPS 500-FMS system is shown using a simple

example. The sample system consists of a transport system, the
distributing and testing stations in the form of product input, the
handling and processing stations combination at the position for
processing and the handling and sorting stations in the form of product
output.

This is how you create an MPS 500-FMS system

When CIROS Advanced Mechatronics is started both the activity
window and the Help window are displayed.
Note In CIROS Advanced Mechatronics Assistant open the folder which

contains the required process model. This is where a functional
description and technical documentation regarding the model are
available.
You can also download some prepared sample systems directly from
the Assistant.
If you do not need the information of the Assistant when starting
CIROS Advanced Mechatronics, then deactivate the entry for
automatically opening the Assistant in the Help menu.

2. Activate the New command in the File menu. Click onto MPS
System.
The Create MPS System window is now displayed.
3. Select a directory to store the new system. Enter the file name.
Under file type, select CIROS Workcells (*.mod). Then click onto
the Save button.

4. The model of a blank system is now displayed. By creating a new

system, some settings in CIROS Advanced Mechatronics are
automatically effected such as:
Changing into the Edit mode,
A table with possible workpieces is made available,
The window Model Libraries is open.
5. A short description of the selected model is displayed if you click

onto Details in the Model Libraries window.
Detailed information regarding the models in the library is available
on the online help in the chapter CIROS Advanced Mechatronics.
Help is started by activating the command Examples and Models of
CIROS Advanced Mechatronics in the Help menu.

6. First, insert the transport system model from the MPS 500-FMS
library by clicking onto Transport System. A preview then displays
the model. Now click onto the Add button.
Alternatively, you can add a model by clicking onto the
corresponding model entry.
The system now consists of the model of the transport system,
which is shown in green as it is still highlighted.

7. Click outside of the model to cancel the highlighting.

Three coupling points are shown on each of the longitudinal sides of
the transport system model. These indicate that the transport
system model can be connected with additional models at these
points.

8. Move the transport system model into the centre of the workspace.
To do so, highlight the model via a mouse click. Then drag the
mouse pointer to the desired position by holding the left mouse
button down.

9. Now add the station combination for product input as a further

model by double clicking onto Product Input.

10. All stations are added at the same position in the workspace. Move
the newly added product input station combination. The operating
position for product input is at the bottom left of the transport
system.
11. The two models are next to one another, but are not yet connected.
To ensure that the operating and transfer points coincide during the
production run of the system, the models must be appropriately
aligned and connected.

12. Now align the model for product input with the transport system
model by clicking onto the grey shaded connecting point of the
stations for product input. Hold down the left mouse button and
drag the connecting point onto the connecting point of the transport
system.
The station combination for product input is now connected to the
transport system.

13. Next enter the station combination for the processing sequence by
double clicking onto Processing in the MPS 500-FMS library. This
station combination is also shown at the predefined position in the
activity window.

14. Connect the newly added, still highlighted model to the lower
middle connecting point of the transport system model by
clicking onto the grey shaded coupling point of the highlighted
processing model. By holding down the left mouse button drag the
coupling point to the lower, middle coupling point of the transport
system model.

15. Finally, add the model for product output. Again, this model is
shown at the predefined position in the activity window.

16. Move the newly added product output station combination. The
operating position for product output is at the top left of the
transport system.

17. Connect the product output model to the top left connecting point of
the transport system.
The highlighting of the model is cancelled as soon as you click
outside of the station model.
18. The system is created. The default communication links used have
been automatically established during modelling of the system.
19. Now exit the Edit Mode and change to the View Mode to obtain a
realistic 3D representation of the system.

This is how you change into the view mode
1. Deactivate the Edit Mode command in the Modeling menu by

clicking onto the Edit Mode command. The check mark next to Edit
Mode is removed.
2. A 3D display of your system is now displayed which also includes a
top view.
3. Close the Model Libraries window. This will give you more space for
the system representation.


Standard Views/Default Settings command in the View menu. With
the commands under View you can move, rotate and zoom to obtain
an appropriate view of your system.

5. The workpiece table can be positioned at a different point within

your workspace at any time. Activate the Edit Mode command in the
Modeling menu and move the workpiece table to the desired
position. Deactivate the Edit Mode command in the Modeling menu
and generate an appropriate view of the system.
The system is created and correctly connected. You can now simulate
system product straight away.

Note If you have newly created or modified the process model of a system, a
save prompt will be displayed when you close the process model.
If you want to save the changes, then answer the prompt with Yes, or
answer the prompt with No, if you want to discard the changes.
4.3 You can modify the model of a system and for example add further
Modifying an existing stations. How you proceed for this and what you need to observe
system depends on what communication links are to be used within the system.
In MPS Standard systems, optical sensors are used as standard to
effect communication.
If the stations of an MPS Standard system are correctly positioned
and connected, using the connecting points, then the
communication links are automatically established by means of this
process.
If you change an MPS Standard system for which you have realised
multi-bit communication via I/O connection, then the
communication links must be re-established.
If you only use the default communication links prepared and want
to establish these, then activate the command Create
Communication Links in the Modeling menu.
All other communication links are to be established in the Manual
Operation window.
Multi-bit communication via I/O connection is available as standard
in MPS 500-FMS systems.
When modelling, or also modifying such a system, the
communication links are set up automatically.
However, if you modify an MPS 500-FMS system where you are not
using the prepared default communication links, you need to set up
the communication links yourself after modelling. User-defined
communication links are set-up in the Manual Operation window.

This is how you modify an already created system

2. Download the desired system by activating the Open command in
the file menu.
3. The Open File window is now displayed.
Workcell (*.MOD) must be set as file type. Change into the directory
in which the process model of the system is stored. Select the
desired file and click onto the Open button.
4. View mode is set as standard. To change the system, change into

edit mode by activating the Edit Mode command in the Modeling
menu.

5. If you want to display information regarding the individual stations

of the system, you need to highlight the respective station via a
mouse click. Highlighted stations are shown in colour.

6. Open the context-sensitive menu via the right mouse button.

Activate the Properties command.
The Object Properties window is now open. The name indicates that
the highlighted station is a testing station.
Close the window when you have obtained all the necessary
information.
Note You will need the Object Properties function if you use a station in a
system several times and wish to identify the individual stations. You
identify a station by its name.
Example: If you are using the buffer station twice in your system, the
name of the station added first is Buffer and the name of the
subsequently added buffer station is Buffer_1.

7. If you now wish to add another station to your system, change to the
top view representation in View by activating the Standard
Views/Top View command in the View menu.

8. Select an appropriate representation of the system via zooming,

moving or rotating the system.
9. Make sure that edit mode is selected. You can establish this by the
check mark next to the command Edit Mode in the Modeling menu.
10. Now open the model libraries by activating the Model Libraries
command in the Modeling menu.
11. In the case of the sample system, this is an MPS Standard system.
For modifications to the system, you will need the stations of the
MPS Stations library. Open the library by clicking onto the +
symbol in front of MPS Stations library.

12. Carry out your modifications to the system. If you want to expand
the system by adding assembly functions, then add for example the
Pick & Place and Fluidic Muscle Press stations between the sorting
and testing stations.

13. To add the desired stations, highlight the sorting station and move
it up.

14. Now insert the Pick & Place station by double clicking the library
entry Pick & Place Station.

15. Position the added station next to the testing station by clicking
onto the highlighted Pick & Place station and move the mouse
pointer to the desired position by holding down the left mouse
button.

16. Connect the new Pick & Place station to the testing station by
clicking onto the bottom, grey shaded coupling point of the Pick &
Place station. Drag the coupling point to the coupling point of the
testing station by holding down the left mouse button.
The testing and Pick & Place stations are now interconnected.

17. Use the same method to add the Fluidic Muscle Press station.
Connect this station to the Pick & Place station.

18. Finally, connect the sorting station to the Fluidic Muscle Press
station.
To do so, highlight the sorting station. Then drag the coupling point
of this station to the unoccupied coupling point of the Fluidic
Muscle Press station whilst holding the left mouse button.
19. The changes to the system are completed. The communication links,
realised via the optical StationLink sensors, are automatically set up
via the correct positioning and connection of the stations.
Close the library and change to the view mode to obtain a realistic
3D display of the system.

20. Deactivate edit mode in the Modeling menu by clicking onto the
Edit Mode command. The check mark next to Edit Mode disappears.

Standard Views/Default Settings command in the View menu. By
using the commands under View you can move, rotate or zoom to
obtain an appropriate view of your system.
22. Save the modified status of the system by activating Save in the File
menu if you want to keep the current file name. Select the Save as
command if you want to save the system under a new name.

Note In the same way as you can expand a system by adding new stations
you can also remove existing stations of a system, whereby you proceed
as follows:
Highlight the respective station. Open the context-sensitive menu via
the right mouse button, where you activate the Remove command. The
station highlighted is removed.
4.4 In MPS system, the communication exchange is realised differently

Creating and monitoring between the individual stations of a system.
communications links in a
system
MPS Standard systems In an MPS Standard systems, communication takes place in the
form of 1-bit connection via optical sensors as standard. As soon as
the stations of a system are correctly positioned and connected with
the help of the coupling points, the optical sensors are also correctly
positioned to transmit communication signals. The prerequisites for
error-free transmission of communication information are therefore
in place.
The absolute addresses of the PLC inputs and outputs of a station
connected to the optical sensors can be found in the allocation list
of the sample PLC program. You will find the technical
documentation and information regarding the sample PLC program
in the CIROS Advanced Mechatronics Assistant.
To open the CIROS Advanced Mechatronics Assistant, activate the
Examples and Models of CIROS Advanced Mechatronics
command in the Help menu.
If you have expanded the 1-bit communication in a MPS Standard
system to multi-bit communication via I/O connection, then you will
need to create the additionally required communication links in the
virtual system.
Only if these communication links have been set up, can the
information exchange between the system stations take place
during simulation.

Different PLC inputs and outputs are available for the transmission
of communication information.
To enable you to work with a networked system promptly, the
communication links between the stations are already prepared.
You can establish these at the click of a button (Modeling/I/O
Configuration/Create Communication Links), whereby specific PLC
outputs of a station are connected to specific PLC inputs of
neighbouring stations. Conversely, a number of PLC inputs of a
station are of course also connected with PLC outputs of
neighbouring stations.
You can see all I/O communication links set up for an MPS system
in the Manual Operation window.
The prepared default communication links are shown as examples for

an MPS Standard system. The system consists of the distributing,
testing and sorting stations. If other MPS Standard stations are
integrated into a system, the connections between the stations are set
up along the above lines.

Distributing station Testing station Sorting station
Optical IP_FI IP_N_FO IP_FI IP_N_FO

sensors
Control I4 Q6 I4 Q6 I4 Q6
console I5 Q7 I5 Q7 I5 Q7
Q4 I6 Q4 I6 Q4 I6
Q5 I7 Q5 I7 Q5 I7
Additional COMM_I0 COMM_Q4 COMM_I0 COMM_Q4 COMM_I0 COMM_Q4

PLC inputs/ COMM_I1 COMM_Q5 COMM_I1 COMM_Q5 COMM_I1 COMM_Q5
outputs for COMM_I2 COMM_Q6 COMM_I2 COMM_Q6 COMM_I2 COMM_Q6
com- COMM_I3 COMM_Q7 COMM_I3 COMM_Q7 COMM_I3 COMM_Q7
munication COMM_Q0 COMM_I4 COMM_Q0 COMM_I4 COMM_Q0 COMM_I4
COMM_Q1 COMM_I5 COMM_Q1 COMM_I5 COMM_Q1 COMM_I5
The prepared default communication links for an MPS Standard system
Note PLC input I5 must be used for communication transfer. Input I5 is

coupled to an EMERGENCY-STOP and indicates whether or not
EMERGENCY-STOP is available.
PLC inputs/outputs COMM_I0 to COMM_I7 and COMM_Q0 to
COMM_Q7 are only available in the case of the virtual MPS stations
for communication. Real MPS stations do not have these
inputs/outputs for communication as standard.
The tables below list the allocation of the symbolic PLC addresses used
for communication to the absolute PLC addresses.

Symbolic Absolute Symbolic Absolute Symbolic Absolute

address address address address address address
IP_FI I0.7 IP_FI I0.7 IP_N_FO Q0.7
IP_N_FO Q0.7
I4 I1.4 I4 I1.4 I4 I1.4
I5 I1.5 I5 I1.5 I5 I1.5
I6 I1.6 I6 I1.6 I6 I1.6
I7 I1.7 I7 I1.7 I7 I1.7
Q4 Q1.4 Q4 Q1.4 Q4 Q1.4
Q5 Q1.5 Q5 Q1.5 Q5 Q1.5
Q6 Q1.6 Q6 Q1.6 Q6 Q1.6
Q7 Q1.7 Q7 Q1.7 Q7 Q1.7
COMM_I0 I2.0 COMM_I0 I2.0 COMM_I0 I2.0


COMM_Q0 Q2.0 COMM_Q0 Q2.0 COMM_Q0 Q2.0
Allocation of symbolic PLC addresses to the absolute PLC addresses for a number of MPS Standard
stations
MPS 500-FMS systems In MPS 500-FMS systems, multi-bit communication is available as

standard. Multi-bit communication is essentially realised via I/O
connection. However, in addition to the coupling of PLC inputs and
outputs, the optical StationLink sensors are used for the
transmission of communication information.
As soon as the stations of a system are correctly positioned and
connected by means of the coupling points, the prepared default I/O
communications links are also automatically established.

The information exchange between the system stations during

simulation can take place.
Both the absolute and symbolic addresses of the PLC
inputs/outputs of a station used for communication can be found in
the allocation list of the sample PLC program. Technical
documentation and information regarding the sample PLC program
of a station can be found in CIROS Advanced Mechatronics
Assistant.
To open CIROS Advanced Mechatronics Assistant, activate the
Examples and Models of CIROS Advanced Mechatronics
command in the Help menu.
Different PLC inputs and outputs are available for the transmission
of communication information.
To enable you to work promptly with a networked system, the
communication links between the stations are prepared. They are
automatically established during modelling or via the press of a
button (Modeling/I/O Configuration/Create Communication Links),
whereby specific PLC inputs and outputs of a station are connected
to the PLC inputs and outputs of neighbouring stations. The sample
PLC programs provided use a part of these communication links.
The communication interfaces between all stations are described in
All I/O communication links established for an MPS system can be
identified in the Manual Operation window.
The prepared communication links are shown as examples for an MPS

500-FMS system. The station consists of the transport system station
and the distributing and testing stations in the form of product input.

Distributing station Testing station Transport system

station
Optical IP_FI IP_N_FO IP_FI

sensors
Control I4 Q6 I4 ST1_OUT0
console I5 Q7 I5 ST1_OUT1
I6 ST1_OUT2
I7 ST1_OUT3
Q4 I6 Q4 ST1_IN0
Q5 I7 Q5 ST1_IN1
Q6 ST1_IN2
Q7 ST1_IN3
Additional COMM_I0 COMM_Q4 COMM_I0 COMM_Q4 ST1_COMM_I0

PLC inputs/ COMM_I1 COMM_Q5 COMM_I1 COMM_Q5 ST1_COMM_I1
outputs for COMM_I2 COMM_Q6 COMM_I2 COMM_Q6 ST1_COMM_I2
communi- COMM_I3 COMM_Q7 COMM_I3 COMM_Q7 ST1_COMM_I3
cation COMM_Q0 COMM_I4 COMM_Q0 COMM_I4 ST1_COMM_Q0
COMM_Q1 COMM_I5 COMM_Q1 COMM_I5 ST1_COMM_Q1
The prepared default communication links for a small MPS 500-FMS system; only working position 1 of the
transport system is allocated
Note The transport system station has the communication interface

shown for each working position. The working position is identical to
the stopper position.
PLC input I5 of the individual stations must not be used for
communication transfer. Input I5 is coupled to the EMERGENCY-
STOP and indicates whether or not EMERGENCY-STOP is available>.
A 1-signal is applied at input 15 if EMERGENCY-STOP is not
actuated.

PLC inputs/outputs COMM_I0 to COMM_I7, COMM_Q0 to

COMM_Q7, ST1_COMM_I0 to ST1_COMM_I3, ST1_COMM_Q0 to
ST1_COMM_Q3 are only available for communication for the virtual
MPS stations. Real MPS stations do not have these input/outputs
as standard for communication.
A description of the communication interfaces between all the
stations of an MPS 500-FMS system and therefore also of the
prepared default communication links can be found in CIROS
Advanced Mechatronics Assistant.
The tables show the allocation of the symbolic PLC addresses used for
communication to the absolute PLC addresses.
Distributing station Testing station Transport system station

address address addresse address address address
IP_FI I0.7 IP_FI I0.7
IP_N_FO Q0.7
I4 I1.4 I4 I1.4 ST1_IN0 I2.0
I5 I1.5 I5 I1.5 ST1_IN1 I2.1
I6 I1.6 I6 I1.6 ST1_IN2 I2.2
I7 I1.7 I7 I1.7 ST1_IN3 I2.3
Q4 Q1.4 Q4 Q1.4 ST1_OUT0 Q2.0
Q5 Q1.5 Q5 Q1.5 ST1_OUT 1 Q2.1
Q6 Q1.6 Q6 Q1.6 ST1_OUT 2 Q2.2
Q7 Q1.7 Q7 Q1.7 ST1_OUT 3 Q2.3

Distributing station Testing station Transport system station

COMM_I0 I2.0 COMM_I0 I2.0 ST1_COMM_I0 I2.4
COMM_I4 I2.4 COMM_I4 I2.4 ST1_COMM_Q0 Q2.4
COMM_Q0 Q2.0 COMM_Q0 Q2.0
Allocation of symbolic PLC addresses to the absolute PLC addresses for a number of MPS 500-FMS stations

Note The transport system station has the communication interface shown
for each of the six working positions. The name of the communication
variable includes a reference to the working position for the purpose of
differentiation. The working position is identical to the stopper position.
The communication variable for working position 2, i.e. the processing
working position, starts with ST2_. These variables do of course have a
different absolute address than the variable starting with ST1_.
You will find the complete list of the communication variables of the
transport system station in CIROS Advanced Mechatronics Assistant.
Display of communication Communication links are created and displayed in the Manual
links Operation window.
The status of a communication link is identified by the graphic

representation of the connection.
Process Activities are displayed in the lefthand part of the window.

These are the variables to which the process model simulation reacts.
You can change the value of these variables in that you can for example
apply 1-signal at a communication input or a valve coil.
The righthand part of the window shows the process activities. These
are the variables which adjust the simulation of the process model. The
user cannot change the value of these variables. Examples of process
activities are sensor signals or also the values of communication
outputs.

Communication links are shown in the middle section. Communication

links form part of the I/O connections.
The signal flow of a communication links runs from right to left. You can
see this by the orientation of the arrow at the end of the links.
The status of a communication link can be identified by the colour of the

links:
Blue: Link is selected,
Red: Link has the value 0,
Green: Link has the value 1.

This is how you establish the prepared default communication links
1. Make sure that the desired MPS is loaded. The example selected
shows an MPS 500-FMS system. This system consists of a
transport system, the distributing and testing stations in the form of
product input and the handling and sorting stations in the form of
product output.

2. Check whether the communication links have already been

established via the coupling of PLC inputs and outputs. To do so,
open the Manual Operation window by activating the Manual
Operation command in the Modeling window.
3. If the middle section of the window with the heading I/O

Connections is not displayed, then open the context-sensitive menu
via the right mouse button.
You open the context-sensitive menu by moving the mouse pointer
into the Manual Operation window and then pressing the right
mouse button. Select the command Show I/O connections.

4. Double click the + symbol in front of the individual stations in the

Manual Operation window to display the entries regarding all the
stations and, insofar as available, also the communication links.
No communication links are displayed in the I/O Connections
window. Therefore, no communication links are established. They
have been deleted by the user at an earlier stage.
5. To create the prepared default communication links activate the

Create Communication Links command in the Modeling menu under
I/O Confiuration.

6. The communication links are set up and shown in the Manual

Operation window under I/O Connections in the form of graphic
connections between the respective communication input/outputs.
7. You can now simulate the running of the prepared PLC programs.
Note In the case of MPS 500-FMS systems the default communication

links used are already created automatically via I/O connection
during the modelling.
Provided that you do not make any changes to the PLC programs
and the communication interfaces, you do not need to create the
communication links.
With MPS Standard systems the prepared communication links
are not automatically created via I/O connection.
If you want to realise multi-bit communication for MPS Standard
systems via I/O connection and use the prepared communication
links for this, you need to create the communication links using the
described menu commands.

This is how you delete the default communication links
1. Make sure that the desired MPS system is loaded. The selected
example shows an MPS 500-FMS system. The system consist of a
transport system, the distributing and testing stations in the form of
product input and the handling and sorting stations as product
output.

2. Activate the Delete Communication Links command under I/O

Configuration in the Modeling menu.
3. All default communication links are now deleted. You can establish
this in the Manual Operation window in the I/O Connections
section. Connections are displayed neither between the
communication inputs/outputs of the distributing and testing
stations nor between the communication input/outputs of the
testing and transport system stations. The same applies for the
product output and transport system stations.
Note The Delete Communication links command deletes all default

communication links. This command does not delete user-defined
communication links.
Delete individual communication connections with the command
Remove I/O Connection in the context sensitive menu for the manual
operation window.

This is how you create user-defined communication links
You can create or delete individual communication links yourself at any

time. It is however important that you use communication interfaces
other than the prepared default interfaces in the PLC programs for the
stations of your system or, for example, if you only want to create
exactly those connections which are evaluated by the PLC programs.
1. Load the desired MPS system. The selected example displays an

MPS Standard system, which consists of the distributing, testing
and sorting stations.

2. Open the Manual Operation window by clicking onto the Manual

Operation command in the Modeling menu. This window is divided
into three parts.
If the middle part of the window with the heading I/O Connections is
not shown, then open the context-sensitive menu via the right
mouse button.
Open the context-sensitive menu by moving the mouse pointer into
the Manual Operation window and then pressing the right mouse
button. Select the Show I/O Connections command.
3. Double click the + Symbol in front of the stations to display all

entries regarding the stations. No connections are shown between
the communication inputs and outputs of the stations.
Consequently, none of the communication links for the system have
been created as yet.

4. You require a connection between the PLC output Q4

Communication of the testing station and the PLC input I6
Communication of the distributing station.
5. In the righthand section of the window scroll down the items of the
testing station into the viewable area of the window.
On the lefthand side of the window scroll down the items of the
distributing station into the viewable section.

6. To establish the desired connection, click onto the Q4

Communication line of the testing station. The line is now
highlighted. Move the mouse pointer onto the blue double arrow
next to the highlighted entry. The mouse pointer now changes into a
rectangle with connection lines.
You can now establish the connections. Press the left mouse button
and whilst holding down the left mouse button, move the mouse
pointer to the arrow next to the entry I6 Communication of the
distributing station. Then release the mouse button again. The
communication link has now been created.
7. If you now click onto Q4 Communication of the testing station, the

entry 16 Communication of the distributing station connected to
this output is automatically highlighted.

8. Next, you want to establish a connection between the PLC input I4

Communication of the testing station and the PLC output Q6
Communication of the distributing station.
9. You now need to select the desired output Q6 Communication of the
distributing station in the righthand window under Process Status.
On the lefthand side of the window then scroll the 14
Communication entry of the testing station into the viewable
section of the window.

10. To establish the desired connection, click onto the entry Q6

Communication of the distributing station. The entry is now
highlighted. Then move the mouse pointer onto the blue double
arrow next to the highlighted entry. The mouse pointer now changes
into a rectangle with connecting lines.
You can now establish the connection. Press the left mouse button
and, whilst holding down the mouse button, move the mouse
pointer up to the arrow next to the 14 Communication entry of the
testing station, then release the mouse button again. The
communication link is now set up.
11. Proceed in the same way if you require further communication links
between the stations of your system.

This is how you delete user-defined communication links
1. Load the desired MPS system. The example selected displays an

MPS Standard system, which consists of the distributing, testing

2. Open the Manual Operation window by clicking onto the Manual

Operation command in the Modeling menu.
If the middle section of the window with the heading I/O
Connections is not displayed, then open the context-sensitive menu
To do so, move the mouse pointer into the Manual Operation
window and then press the right mouse button. Now select the
Show I/O Connections command.
3. Double click the + symbol of the individual stations to display the

entries for the stations.

4. Click onto the entry, whose connection you want to delete. In this
exampIe, this is the I4 Communication entry of the testing station.
If you want to see the communication output with which
14 Communication is connected, then scroll down in the righthand
section of the window until the connection is fully displayed.

5. Click onto the I4 Communication entry of the testing station again

or onto the associated entry Q6 Communication of the distributing
station. Open the context-sensitive menu via the right mouse button
and select the Remove IO Connection command.
6. The communication link has been deleted.

4.5 The production run of the system can be simulated as soon as a system
Simulating a system is modelled and the necessary communication links are set up.
The following preconditions must be fulfilled for MPS Standard

systems:
The stations must be correctly positioned next to each other and
connected.
If the stations are correctly positioned, then the position and
alignment of the StationLink sensor which transmit the
communication signal are also correct. The communication links are
thus correctly established.

A PLC program which controls the operation of the station must be

available for each station.
The PLC program can be executed either via the internal S7 PLC or
an external controller.
If you are using the default settings of the software, then the sample
PLC program of the station is automatically loaded to the internal S7
PLC and executed when simulation is started.
If no PLC program is active, then the user can systematically control
individual process components of the system by using the manual
operation window functions.
Note The user can disconnect the connection between station models and
PLC selectively in order to manually control individual process
components.
The prerequisites for MPS 500-FMS systems are as follows:

The stations must be correctly positioned and aligned with the
transport system.
The communication links between the PLC inputs and outputs of the
stations must be established. This is effected automatically for the
prepared communication links as a result of the correct positioning
and alignment of the stations on the transport system.
A PLC program must be available for each station, which controls the
operation of the station.
The PLC program can be executed either via the internal S7 PLC or
an external controller.
If you are using the default settings of the software, then the sample
PLC program of the station is automatically loaded to the internal S7
PLC and executed.
If no PLC program is active, then the user can selectively control
individual process components of the system using the manual
operation window functions.
If you simulate a system that is incorrectly configured, the individual

process components will behave differently during simulation than
expected.

As soon as system simulation is active, you can monitor the visual

simulation and therefore the production sequence of the system in the
activity window.
Certain information is always available to you.

The file name and path data of the loaded system are shown in the
header line.
The status bar informs you regarding the operating status of the
system:
A field to the right displays whether simulation is active or stopped.

Stopped: The simulation mode is not active. The system is not
being simulated
Not simulated.
Cycle: The system is being simulated.
Running: The system is being simulated.
The field on the left indicates the simulation time.
Note In CIROS Advanced Mechatronics the two simulation modes Cycle and
Running are identical.

This is how simulation is switched on and off again
1. Make sure that the system is in the initial position by executing the
Reset Workcell command in the Simulation menu.
2. Activate the Start command in the Simulation menu.
The simulation is active. You can identify the simulation mode in the
status line via the Running entry.
Alternatively you can also activate simulation via the Start Cycle
menu entry or via the Stopped button in the status bar.
3. To stop simulation, click Stop in the Simulation menu.

Alternatively you also click onto the Running field in the status bar.

As soon as simulation is active, you can operate and monitor the

system.
Note Proceed as follows if you want to save a modelled system after

simulation is executed: First activate the command Reset Workcell in
the Simulation menu. The system moves into the initial position. All
workpieces are removed. Then activate the required command to save
the system.
4.6 If system simulation is active, you can operate each station controlled
Operating and monitoring via the sample PLC program using the pushbuttons and switches of the
a system corresponding control console. You can identify the status of simulation
on the status bar.
Process module
Control console of MPS Standard station Control console of transport system station
I4
I5
Start Stop
Q4
Reset Auto/Man
Q5
GND
Q1 Q2
I/O

Depending on the system combination, different production processes

are executed. Pneumatic cylinders or measuring instruments can be
produced. The individual production processes require different
workpieces. Missing parts are designated for individual stations.
Workpieces Suitable for systems with
Correct workpieces: Basic Processing station

cylinder body of different types Storage station
Buffer station
Testing station
Black
Robot station
Robot assembly station
Red Sorting station
Separating station
Metal Distributing station
Workpiece of incorrect height Processing station

and incorrectly drilled hole: Testing station
Basic cylinder body
Blue
Correct workpieces: Processing station

Housings for measuring Fluidic Muscle Press station
instruments in different designs Storage station
Pick & Place station
Buffer station
Black
Testing station
Sorting station
Red Separating station
Distributing station
Metal

Correct intermediate product: Fluidic Muscle Press

Housing for measuring Storage station
instrument with applied Buffer station
measuring insert in different
designs
Black
Red
Metal
Workpiece for MPS Standard systems

Correct workpieces: Basic Distributing station

cylinder body of different types Testing station
Processing station
Handling station
Black
Quality assurance station
Sorting station
Red Robot assembly station
Storage station
Metal
Workpiece of incorrect height Testing station

and incorrectly drilled hole
Blue
Working with incorrectly drilled Processing station

hole: Quality assurance station
Housing for measuring Robot assembly station
instrument in different designs
Black
Red
Metal
Workpieces for MPS 500-FMS systems

As soon as you create a new system, a table with the possible

workpieces is displayed as standard. If simulation is active, then select
the workpiece from this table which you want to use for the production
process of the system.

This is how you operate an MPS Standard system where the

individual stations are controlled via the sample PLC programs
1. Make sure that the system is in the initial position and that there are
no workpiece on the stations. You realise this by activating the
Reset Workcell command in the Simulation menu.
2. Start simulation by clicking the Start command in the Simulation

menu.
3. The illuminated Reset button now prompts the reset function on all
stations.

4. Carry out the reset function for each station by clicking onto the
Reset button. We recommend that you carry out the resetting of the
individual stations against the material flow.
5. The illuminated Start button of a station indicates that the

corresponding station is now in the initial position and the start
precondition is fulfilled.
6. Make sure that workpieces are available for the production process
of the system. In the case of the system shown this means that the
magazine of the distributing station must be filled with workpieces.

7. Click onto the desired workpiece on the table of workpieces. All

workpieces are realised in the form of buttons. The selected
workpiece, a red basic cylinder body, is shown as pressed.
Then click onto the symbolic workpiece on the distributing station.
With each mouse click the magazine is filled with the workpiece
selected.
Note Not every workpiece is suitable for every station. If you have selected a
workpiece which cannot be processed by a station, this workpiece
cannot not be generated for the station.

8. Start the sequence of each station by clicking onto the Start button.
This starts the automatic mode of the station. We recommend that
you start the stations in the sequence in which they are arranged in
the material flow.
9. With the key actuator you can choose between continuous cycle
(switch position vertical) and individual cycle (switch position
horizontal) for the sequence of a station.
10. You can interrupt the sequence of a station at any time by pressing
the STOP button. If you want to restart the station, you need to carry
out the Reset function beforehand.

If a station is controlled via a PLC program you have created, then you
will know how the running and operation of the station are defined.
If a station is not controlled via a PLC program, you can selectively
trigger the process actuators manually. You will need the manual
operation window functions for this.
Note Slides filled with workpieces, which result in the production process
stopping, can be emptied via appropriate commands in the manual
operation window.

This is how you operate an MPS 500-FMS system where the

individual stations are controlled via the sample PLC programs
The operation of an MPS 500-FMS system is described using the

example of a fully expanded MPS 500-FMS system.
1. Make sure that the system is in the initial position and that there are
no workpieces on the stations. This applies in particular to the
pallets of the transport system station, the storage slots of the
automated warehouse station and the slides of the sorting station.
Remove all workpieces by activating the Reset Workcell command
in the Simulation menu.

2. Start the simulation by clicking the Start command in the Execute

menu.
3. The starting of simulation causes the master switch on the system to
be switched on. The master switch supplies the whole system with
power. The master switch is located on the side of the control
cabinet of the transport system station.
4. First, you start the transport system station. The flashing Automatic
On button prompts the start function. Click onto the Automatic On
button. The transport system is running and the Automatic Off
button is illuminated.

5. In the case of the stations at the operating positions Product Input,

Processing, Assembly and Product Output, the illuminated Reset
button prompts the reset function.
6. Carry out the reset function for the stations mentioned by clicking
onto the Reset button.

7. In the case of the automated warehouse station it is equally

mandatory to carry out the reset function. However, for reasons
specific to this station, the reset sequence of the automated
warehouse station is different to that of the MPSs stations.
To reset the station, switch the AUTO/MAN key actuator into the
MAN position (switch position horizontal) by clicking onto the
AUTO/MAN key actuator. The flashing Reset button indicates that
the station can now be reset.
8. Click onto the Reset button.

The automated storage station moves into the initial position. The
axis carries out reference travel and the Start button flashes when
the initial position is reached.

9. Now switch the AUTO/MAN key actuator to the AUTO switching

position (switch position vertical). Automatic operation of the
station can only be started in this switching position. Start the
sequence of the station by clicking the Start button.
10. The illuminated Start button on the MPS stations indicates that
the corresponding stations are in the initial position and that the
start precondition is fulfilled.
11. As soon as you have filled the magazine of the distributing station
with workpieces, i.e. with basic cylinder bodies, the start
precondition for this station is also fulfilled. The Start button is
illuminated.

12. Fill the magazine by clicking onto the desired workpiece on the
workpiece table. The selected workpiece, a red basic cylinder body,
is shown depressed.
Then click onto the symbolic workpiece on the distributing station.
With each mouse click the magazine is filled with the workpiece
selected.
13. Start the sequence of each station by clicking onto the Start button.
14. With the AUTO/MAN key actuator you can choose between
continuous cycle (switching position vertical) and individual cycle
(switching position horizontal) for the sequence of a station.

15. You can interrupt the sequence of a station at any time by pressing
the STOP button. If you want to restart the station, you need to carry
out the Reset function beforehand.
Note regarding the The automated warehouse station only participates actively in the
automated warehouse production process if product output for the process is not or is no
station longer available for the process.
In concrete terms this means:

The automated warehouse stocks up if
one or both stations of product output are not started or
the slides at product output are full.
The automated warehouse takes out workpieces if

an empty pallet passes.
Note regarding the quality The quality assurance station identifies the housing for a measuring
assurance station instrument as a reject part. The station passes on this information to the
transport system station and the transport system station passes on the
information to the robot assembly station. The robot then rejects the
transferred reject part.
Note If a station is controlled via a PLC program you have created, you will
know how the running and operation of the station is defined.
If the station is not controlled via a PLC, you selectively trigger the
process actuators manually. You will need the functions of the
Manual Operation window for this.
Slides filled with workpieces and which result in the production
process stopping, can be emptied using appropriate commands in
the Manual Operation window.

This is how the status of an MPS system is indicated
process components.
The LEDs on the inputs/outputs on the control console, provided for
the I/O connection, indicate the status of the communication
signals.
If air is applied at a cylinder connection, the connection is
highlighted in blue.
The pneumatic tubing itself is not shown.
In the windows Inputs and Outputs you can identify the status of the
PLC signals for the station selected.
The Manual Operation window provides you with an overview of all
process statuses and process activities of the system and also
displays all the communication links.
The designation of a component is shown by clicking onto the
connection or the LED of a process component. This designation is
identical to the designation in the circuit diagram.
One exception is the designations of the supply ports. These form
part of the valves which supply the supply port with air.


Note You can also display additional information regarding the sensors. The
settings for this are effected in model explorer.
Activate the command Model Explorer in the Modeling menu.
A tree structure is displayed.
Click onto the top entry. In the case of an MPS 500-FMS system,
the entry is MPS 500.
Now activate the context-sensitive menu via the right mouse button
and select the Properties command.
The window Properties for workcell is displayed.
Activate the Sensor Simulation register.
In the Visualisation section click onto the two check boxes for the
entries Show Measuring Range and Show Measured Value(s). Both
boxes are now shown with a tick.

Close the Properties for workcell window.

Close the Model Explorer window.
The respective sensor lines are now shown in the system.

4.7 You can freely adjust the perspective view of a modeled system. With a
Changing the view of a few central commands you can rotate, move, enlarge or minimize the
system representation of the process model.

The perspective view is defined by the coordinates of the viewer (=

standpoint) and a reference point of the process model (= mid point).
Reference point
Turn Angle
Z
Definition of perspective view

This is how you move the modeled system
1. Activate the Move command in the View menu.

The mouse pointer now changes into a small coordinate system,
which indicates the direction in which the standpoint and reference
point can be moved. A dashed arrow means that it is not possible to
move into the corresponding direction.
2. Hold down the left mouse button.
3. Move the mouse pointer in the Z or X direction.
4. Release the mouse pointer again.
The view then changes accordingly.
You can also activate the Move command by holding down the Shift key
and then pressing the left mouse button.
This is how you rotate the modeled system
1. Activate the Rotate command in the View menu.

The mouse pointer changes into a small coordinate system, which
indicates the direction in which the standpoint and reference point
can be moved. A dashed arrow means that it is not possible to move
in the corresponding direction.
2. Hold down the left mouse button.
3. Move the mouse pointer in the Z or X direction.
4. Release the mouse pointer again.
The view then changes accordingly.
You can also activate the Rotate command by holding down the Ctrl key
and then pressing the left mouse button.
To tilt the system in any direction, hold down the Alt key and left mouse
button and move the mouse.

This is how you enlarge or reduce the view
1. Activate the Zoom command in the View menu.

The mouse pointer changes into two squares.
2. If you want to enlarge the view, then hold down the left mouse
button and move the mouse pointer in the direction of the arrow.
3. If you want to reduce the view, then hold down the left mouse
button and move the mouse pointer against the direction of the
arrow.
You can also activate the Zoom command by holding down the key
combination Shift+Ctrl and then pressing the left mouse button.
If you have a mouse with a scroll wheel, you can easily enlarge or
minimise the system view by using the scroll wheel.
This is how you enlarge a specific section
1. Position the mouse pointer on a corner of the section.

2. Hold down the key combination Shift+Ctrl.
3. Press the right mouse button and move the mouse. A frame is now
displayed.
4. By moving the mouse, place the frame around the section you want
to enlarge.
5. Release the right mouse button and the section is now enlarged.
This is how you enlarge the view
Activate the Zoom-In command in the View menu. The picture is

enlarged to 125%.
This is how you reduce the view
Activate the Zoom-Out command in the View menu. The picture is now
reduced to 80%.

4.8 The Inputs and Outputs windows show which signals are applied at the
The Inputs and Outputs inputs and outputs of the PLC for the selected station. 0 signals are
windows shown in red and 1 signals in green. If the input or output signal is
forced, the value is shown in angle brackets, e.g. <1>.
The PLC inputs/outputs available for communication are designated

differently in MPS Standard systems and MPS 500-FMS systems.
In MPS Standard systems you will find

Panel_I4, Panel_I6, Panel_I7, Panel_Q4, Panel_Q5, Panel_Q6,
Panel_Q7
for the PLC inputs/outputs available on the control console for I/O
connection.
COMM_I0 COMM_I7, COMM_Q0 COMM_Q7
as additional inputs/outputs for I/O connection.

In MPS 500-FMS systems for example, PLC inputs/outputs of the

transport system station have an identifier, whereby PLC inputs/outputs
can be allocated to the individual stopper positions.

This is how you open the Inputs window
1. Make sure that the desired system is loaded and simulation is

active.

2. Select the station whose PLC inputs you wish to observe. To do so,
click onto the Controller Selection in the Programming menu. Select
the desired PLC in the Current column via a mouse click.
Note The Controller Selection window displays all the stations of the
modelled system which have their own internal controller. The
controllers are switched to active by default. If system simulation is
started, for example via the Start command in the Simulation menu,
then the PLC programs of the active controllers are started in
sequence4. If system simulation is stopped, the execution of the PLC
programs in the active controllers is also stopped. The status as to
whether or not a PLC is operating is shown in the Start/Stop column.

The status of PLC inputs/outputs is displayed in the Inputs/Outputs

window only for the controller selected as Current. Also, PLC programs
can be loaded to the selected internal controller. To do so, use for
example the Open command in the File menu.
3. Activate Inputs/Outputs in the View menu and select Show Inputs.
So that you know which process signal it is, the signal names include
the relevant designations from the circuit diagrams.
Example: STATION_1B2: The PLC input which is connected to sensor
1B2.

This is how you open the Outputs window
1. Make sure that the desired system is loaded and simulation is

active.

2. Select the stations whose PLC you wish to observe by clicking onto
the Controller Selection command in the Programming menu.
Select the desired PLC in the Current column.
Note The Controller Selection window displays all the stations of the
modelled system which have their own internal controller. The
controllers are switched as active by default. If simulation of the system
is started, for example via the Start command in the Simulation menu,
the PLC programs of the active controllers are started in sequence. If
system simulation is stopped, then the execution of the PLC programs is
also stopped in the active controllers. The status as to whether or not a
PLC is operating is displayed in the Start/Stop column.

The status of PLC inputs/outputs is displayed in the Inputs/Outputs

window only for the controller selected as Current. Also, PLC programs
can be loaded to the selected controller. To do so, use for example the
Open command in the File menu.
3. Activate Inputs/Outputs in the View menu and select Show

Outputs.

So that you know which process signal it is the signal names include the
relevant designation from the circuit diagrams.
Example: STATION_1M1: The PLC output which is connected to valve
coil 1M1.
Note It is of course possible to open the Inputs and Outputs windows at

the same time.
You can also open the Inputs and Outputs windows via Workspaces
in the Windows menu, where you will find the frequently required
window combinations.
4.9 The Manual Operation window offers various functions:

The Manual Operation Display of the process statuses and process activities of a system,
window Controlling of individual actuators of a system,
Display of communication links realised via I/O connection,
Creating of user defined communication links via I/O connection,
Setting of stops in the simulation of a system.
The entries for the individual stations of a system are configured in a

tree structure. By double clicking onto the + symbol of a station, all
entries are displayed regarding the respective station. A double click
onto the minus symbol hides the entries again.

The lefthand section of the window displays the process activities.

These include primarily the actuation of valves and the controlling of
communication inputs. 1 signals are indicated by a red illuminated LED.
Process activities are variables to which the process model simulation
reacts. As the user, you can change the value of this variable.
You can monitor all process activities in the righthand section of the
window.
The process statuses include status of sensors, valve coils and
communication outputs. Here, 1 signals are indicated by a green
illuminated LED.
Process statuses are variables that are set and correspondingly
displayed by the process model simulation. The user cannot change the
value of these variables.
The status of signals is also shown in the Value column. If the signal is
forced, the value is shown in angled brackets.
You can show or hide the display of the Value column. You will find the
relevant command in the context-sensitive menu via the right mouse
button.

Additional information is also displayed: If the signal status has

changed since the last simulation cycle, the relevant line is highlighted
in colour. This enables you to easily identify and follow the signals that
have last changed. If the Value Change is not shown in colour, then
activate Show Value Changes in the context-sensitive menu via the
right mouse button.
Communication links are shown in the middle section of the window.

Communication links form part of the I/O connections.

The signal flow of a communication link runs from right to left. You can
see this by the orientation of the arrows at the connection ends.
You can identify the status of a communication link by the colour

marking of the connection:
Blue: Connection is selected,
Red: Connection has the value 0,
Green: Connection has the value 1.
By clicking onto an entry for which a communication link exists, the

respective communication user is also shown highlighted.
If the middle section of the window headed I/O Connections is not

displayed, then activate Show I/O Connections in the context-sensitive
menu via the right mouse button.

Additional information I/O connections are connections between the inputs and outputs of the
regarding the I/O system.
connections
Differentiation should be made between
PLC inputs and outputs on the controller side,
Process inputs and outputs on the process side.
PLC outputs, for example the signal for a valve coil, are input signals for
the process.
Conversely the process generates output signals, for example sensor
signals, which are then connected to a PLC input.
These connections between PLC inputs/outputs and process

inputs/outputs also form part of the I/O connections and are required
internally by CIROS Advanced Mechatronics. They are taken into
account in the Manual Operation window, but are not fully displayed.
The Manual Operation window is used solely to manage the

communication links realised via I/O connection.
The table below provides an overview of the meaning of the symbols by

the entries in the window section I/O Connections.

Symbol Meaning
Process inputs Not connected
Connected, but with output not displayed
Connected with displayed output
Inverted connection with one displayed

output
Forced to the value 0
Process outputs Not connected
Connected, but with input not displayed
Connected with one or several displayed

outputs
Important You may only delete those I/O connections, which you have created
yourself as communication links. Otherwise it may no longer be
possible to simulate the system correctly.

This is how you open the Manual Operation window
1. Make sure that the desired system is loaded. The example selected
shows an MPS Standard system, which is made up of the
distributing, testing and sorting stations.

2. Activate Manual Operation in the Modeling menu. Alternatively,

open the window by activating Manual Operation under
Workspaces in the Windows menu.

3. Now double click the + symbol of those stations whose process

statuses and process activities you want to monitor or control.
The example shows the process statuses and process activities for
the distributing station.
Note You can show or hide the middle section of the Manual Operation
window headed I/O Connections as required. To do so, activate or
deactivate the Show I/O Connections command in the context-sensitive
menu via the right mouse button.

This is how you control individual actuators of a system
If you want to manually actuate individual actuators of a system or

selectively set communication signals, we recommend that you
disconnect the respective stations of the system from their controllers.
In this way only the commands triggered via manual operation will be
executed. The PLC programs are no longer active. This procedure
prevents the output of conflicting commands to process components.
You may however also want or need to intervene manually in the

running of a station controlled via a PLC program. This enables you to
correct faulty process signals so that the sequence of a process
continues to be executed. Or you can simulate communication signals
of neighbouring stations and therefore test and commission individual
PLC programs.
If you want to terminate manual operation and the respective station or

selected stations are to be controlled via the PLC programs again, then
reconnected the system with controller of the stations again.
1. Make sure that simulation is stopped.

2. Open the Manual Operation window by activating Manual
Operation in the Modeling menu.

3. Disconnect the system from the controllers.

Move the mouse pointer into the left section of the Manual
Operation window to the process activities. Press the right mouse
button to open a context-sensitive menu and select the Disconnect
All Controllers command.
Note You can of course also disconnect the controller from just one station.
To do so, highlight the required station in the Process Activity section of
the Manual Operation window. Then open the context-sensitive menu
via the right mouse button and select the Disconnect Selected
Controllers command.

4. Start the simulation.

5. Double click the line of the process activity you wish to execute. The
double click causes the value of the signal to change.
If you double click a line with a valve actuation, then the value of the
corresponding valve coil changes. If the value 0 applies, this is set to
1 and vice versa. The double click therefore has a toggle function.
Please note: To switch a valve with two valve coils into a specific
switching position, the appropriate signal must be applied at both
valve coils.
6. Stop the simulation if you wish to terminate manual operation.

7. To control the system via the PLC programs in the controllers again,
move the mouse pointer into the left section of the Manual
Operation window to the Process Activities. Open the context-
sensitive menu via the right mouse button and select the Restore
I/O Connections command.
Notes The execution of the Reset Workcell command in the Simulation menu
also causes the inputs/outputs of the system to be reconnected to the
inputs/outputs of the controllers.

This is how you set the stops in the operation of a system
If you want to stop the operation of a system at a defined point, then

you need to set stops within the simulation of the system. You can stop
the execution of a process whenever the value of a process signal
changes.
The stops merely influence the simulation of the system, the PLC
programs for the control of the system remain unaffected. If a stop is
applied to a signal, the system simulation stops if the signal value
changes. The changed signal value is transmitted to the system as soon
as simulation is restarted.
1. Make sure that the desired system is loaded.

2. Start the system simulation and make sure that the system is
controlled via the PLC programs.
Open the Controller Selection window if the system is controlled via
the sample PLC programs of the individual stations. To do so, click
onto the Controller Selection command in the Programming menu.
By the symbol of the green arrowhead in the Start/Stop column you
will see that all three controllers of the system shown are operating
and the PLC programs are being executed in the controllers.


If the window is in three parts, you can hide the middle I/O
Connections section since this section is not required when working
with stops. To hide the I/O Connections window section, deactivate
the Show I/O Connections command in the context-sensitive menu

4. Double click the + symbol for the-example of the distributing

station to display all the process activities of this station.
Now click onto the line of the required process activity, in the case of
this example line 2, to control the valve coil 1M1 for the ejector slide
of the magazine. Press the right mouse button to open the context-
sensitive menu and select Stop at Value Change.

5. The stop symbol in the line in the Manual Operation window

indicates that a stop is set at this signal.

6. Operate the process. As soon as the PLC of the distributing station

generates a 1 signal at valve coil 1M1, simulation stops. You can
follow the status of simulation at the status bar.
7. The process is continued if you restart simulation of the system. The

ejecting slide of the magazine ejects a workpiece.

8. If you want to delete the stop, click onto the line with the stop point
with the right mouse button. Open the context-sensitive menu via
the right mouse button and select the command Stop at Value
Change. This command is realised in the form of a toggle function.
The stop is removed. Alternatively you can also select the Delete All
Stops command.
Note that you can also set stop at the signals in the Process Status
section of the window.

This is how you control the operation of a system step by step
Use the Manual Operation window as a tool to control the simulation if

you want to execute the sequence of the process step by step. You can
stop the process at defined points by setting stops.
To execute the process step by step, set the stops at the process
activities of a station or of several stations. With this procedure the
process is stopped whenever an actuator of the respective station
changes its status. If you also want to take into consideration and
monitor communication signal during the step by step operation, then
you need to set the stops at the corresponding signals in the window
section Process Activity and Process Status.
1. Make sure that the required system is loaded. It is generally helpful

if the system is in the initial position.

2. Start simulation of the system and make sure that the system is
controlled via PLC programs. You can establish the operational
status of the individual controllers in the Controller Selection
window.

4. If the I/O connections are displayed in the Manual Operation
window, then hide these.

5. Double click the + symbol, for example of the distributing station, to

display all the process activities of this station.
Under Process Activity , highlight all lines which contain signals for
valve coils by pressing the Ctrl key and clicking onto the desired
lines with the left mouse button.
Open the context-sensitive menu via the right mouse button and
select Stop at Value Change.

6. All lines with valve coils now show stops.

7. If you also want to monitor communication, then you need to

similarly set stops at the corresponding communication signals.
In the case of MPS Standard systems, the communication exchange
takes place via optical sensors. For the distributing station only the
optical sensor IP_FI needs to be considered.
8. Operate the process using the pushbuttons and switches of the

station control consoles. The simulation stops whenever the status
of a process signal of the distributing station changes. The process
continues to be executed when you restart the simulation.

9. Open the context-sensitive menu via the right mouse button if you
want to remove the stops again. Select the Delete All Stops entry,
doing so for both window sections.

4.10 Each station is equipped with an internal PLC. A SIMATIC S7 simulator is

Controlling a system used as internal PLC. The S7 simulator interprets executable S7
using the internal S7 PLC programs.
A sample PLC program for S7-300 is available for each station. When
you load a station from the library, the sample PLC program is
automatically loaded to the internal PLC of the respective station. Once
simulation of the system is started the internal PLC executes the S
program. You can of course also download a different S7 program to the
internal PLC of a station. If doing so, you need to keep in mind the
following: Only complete project files with the file extension S7P can be
loaded. The projects must have been created with the SIMATIC Manager
and conform to the Siemens MC7 code at the binary level. This is the
case with all STEP-7 programs created in LDR, FCH, STL or GRAPH.

This is how you control a station using a corresponding sample PLC

program
1. Load the desired MPS system. The sample selected displays an MPS
Standard system. The system is made up of the distributing, testing
2. The supplied sample PLC program for each station is loaded by

default to the corresponding internal PLC.
3. As soon as simulation of the system is started, the PLC programs of
the individual stations are also executed.
Activate Start command in the Simulation menu.

Note If you have modified the PLC program for a station in the corresponding
internal PLC, the modified PLC program will of course be executed once
simulation is started.
This is how you control a station using a newly created S7 PLC

program
1. Load the desired MPS station.

3. Select the station whose PLC program you want to modify. The PLC
program is to be executed by the internal PLC.
To do so, activate the Controller Selection command in the
Programming menu. In the Controller Selection window click on to
the required station in the Currentcolumn.
4. Select the Open command in the File menu to open the Open File
window.

5. Under file type, select S7 Project (*.S7P).

All the files of this format available in the active directory are
displayed.
6. Navigate to the directory which contains your S7 project.

Select the required S7 project and click onto Open.

7. If the project you have selected contains several S7 programs, select

the one required for the simulation and confirm this with OK.
8. Start simulation of the system. Select the Start command in the

Simulation menu. Once simulation of the system starts the PLC
programs of the individual stations are also started. The newly
loaded PLC program of the internal PLC is executed for the station
you have selected.
Note Another option is also available for loading PLC programs to the internal
PLC of station.

This is how you load a PLC program to an internal PLC (alternative

method)
1. Make sure that the desired MPS system is loaded.

3. Open the S7 Program Manager by activating the S7 Program
Manager command in the Programming menu.

4. The just loaded PLC program for each internal PLC is shown in a
clearly set out tree structure.
Click onto the + symbol in front of the station whose PLC program
you want to change. In the exampIe the testing station has been
selected. Highlight the Program entry.

5. Open the context-sensitive menu via the right mouse button and
select the Load command.
6. The Open window is now displayed.

7. Navigate to the directory which contains your S7 project.

Select the desired S7 project and click onto the Open button.
8. If the project you have selected contains several S7 programs, select

the one required for simulation. Confirm your selection with OK.
The required PLC program is loaded. You can now simulate the
operation of the system.

This is how you establish which S7 program in the internal PLC of a

station has just been loaded
1. Make sure that the desired MPS system is loaded.
2. Activate the S7 Program Manager command in the Programming

menu.

3. A clearly set out tree structure shows the just loaded PLC program
for each internal PLC.
4. Click onto the + symbol to display the name and structure of the PLC
program.
The PLC program can consist of the following modules: Organisation
modules, data modules, functions and system functions.

5. Click onto the + symbol again to display the modules of the PLC
programs.
You can view the contents of the module by double clicking onto a
module.
Further information regarding the display of S7 programs in STL or the

display and use of timing diagrams can be found in the online Help.

This is how the sample PLC programs are filed on the computer
1. Select the Open command in the File menu. The Open File window is
now displayed.
2. Select S7 Project (*.S7P) under file type.
All the files of this format available in the active directory are
displayed.

3. Navigate into the directory in which you have installed the Software
package CIROS Advanced Mechatronics software package. From
there change to the directory \CIROS Advanced
Mechatronics\bin\FD_PLC_ADV\S7 where four subdirectories are
shown.
The directory MPSC_V22 contains the S7 project mpsc_v22.s7p,
where you will find the sample PLC programs for all MPS
Standard stations.
The directory FMS50__1 contains the sample PLC programs for
the transport system of MPS 500-FMS systems.
The directory 313C__1 contains the sample PLC programs for the
individual stations of MPS 500-FMS systems.
The directory Store contains the sample PLC programs for the
automated warehouse station.
4. As an example, change to the directory MPSC_V22. Select the

S7 project and click onto Open.

The program name provides information about the PLC program and the
station model to which it belongs:
The initial digit corresponds to the station number.
The two letters after the first digit indicate the station:
VE: Distributing station
PR: Testing station
BE: Processing station
HA: Handling station
PU: Buffer station
MO: Assembly station
SO: Sorting station
PP: Pick&Place station
FM: Fluidic Muscle Press station
TR: Separating station
LA: Storage station
The letters starting with underscore indicate the programming
language of the PLC program:
AS: The programming language GRAPH,
KFA: The programming languages LDR, FCH and STL,
The internal PLC supports to a large extent the command set of the S7-
400 controllers, whereby the programs can be created in ladder
diagram, function chart, statement list or in the form of graphic
sequence control.

5. Close the window by clicking on the Cancel button.
Note You must never modify the sample PLC programs shown here because
these are the standard default programs required for the simulation of
an MPS system.
If you want to make changes to the PLC programs, then install these a
second time using the specially provided installation command of
4.11 S7-PLCSIM is a soft PLC, which executes the PLC programs created in
Controlling a system STEP 7. A wide range of different testing and diagnostic functions for
station using the external fault finding in the PLC program are available within STEP 7. These
Soft PLC S7-PLCSIM testing and diagnostic functions include for example the status display
of variables or the online display of the PLC program. You can use these
functions if you create the PLC program for a station of a system in
STEP-7 and then test the PLC program in conjunction with the
simulation of the system.
The exchange of PLC input/output signals between the system and the
soft PLC S7-PLCSIM is effected via the EzOPC program. The EzOPC
program forms part of the CIROS Automation Suite and has been
installed on your PC together with the CIROS Advanced Mechatronics
application.
EzOPC is automatically invoked by CIROS Advanced Mechatronics as
soon as you start simulation of the system. The prerequisite for starting
EzOPC is of course that at least one station of the system is controlled
via an external PLC.
Note If you work with the operating system Vista, please make sure that the
used S7-PLCSIM-Version is Vista compatible.

To ensure that the exchange of PLC input/output signals with the

selected station is correctly effected, the following requirements must
be met:
When starting EzOPC, both communication users S7-PLCSIM and
simulation of the system must be active. Only then can EzOPC set
up the communication link to both users.
The EzOPC program must be correctly configured for the exchange of
data. Therefore check the configuration as soon as EzOPC is started.
Configuration of EzOPC for data exchange with S7-PLCSIM

This is how you control a station of the virtual system using S7-
PLCSIM
1. Start STEP 7 or then STEP 7 Manager and open the desired S7

project.
2. Start S7-PLCSIM by clicking onto the menu item Simulate Modules
under Extras.

3. The window of S7-PLCSIM is opened.

Enter the input/output bytes you want to exchange and monitor.
4. Delete the contents of the virtual CPU of S7-PLCSIM by clicking onto

MRES in the CPU window.

5. Download the required PLC program to the S7-PLCSIM by

highlighting the modules folder. Then activate the Download
command in the PLC menu.
The PLC program is to control a selected station in a virtual MPS
system in CIROS Advanced Mechatronics. The selected station to
be controlled via S7-PLCSIM is the distributing station.

6. Load the appropriate MPS system in CIROS Advanced

Mechatronics.
7. Make the necessary setting for the desired station, i.e. that this is to
be controlled via an external PLC by activating the Switch external
PLC internal PLC command in the Modeling menu.

8. The Switch external PLC internal PLC window is now opened.

The columns Type and Program Name/OPC Server show the
information for the controller of the selected station.
As an example consider the entries for the distributing station:
The name of the station is Distributing.
The station is controlled via the internal PLC. You can establish
this by the S7 PLC simulator entry.
The internal PLC executes a PLC program, which is part of the
STEP 7 project MPSC_V22.S7P with specified path.
9. Highlight the desired station via mouse click. Activate the context-
sensitive menu via the right mouse button and select the Switch
command.
Alternatively changeover the controller by double clicking the
desired station.

10. For the selected station OPC server is now entered in the Type
column. The name FestoDidactic.EzOPC.2 is now displayed under
program name/OPC server. This entry means the process signals for
the selected station are exchanged via an OPC server named
FestoDidactic.EzOPC.2.
11. Close the Switch external PLC internal PLC window.

12. Check whether the system should be in the initial position. If so,
activate Reset Workcell command in the Simulation menu.

13. Start simulation of the system by activating Start in the Simulation

menu.
When simulation is started the EzOPC progam is automatically
invoked. You can establish this by the EzOPC entry in the bar.

Note With the starting of system simulation, the communication program

EzOPC is also started. When EzOPC is started, both communication
users - S7-PLCSIM and the simulation of the system must already be
active. Only then are the communication links correctly set up.
14. Click onto EzOPC in the start bar. The EzOPC window is now
displayed, where you configure the communication between CIROS
Advanced Mechatronics and S7-PLCSIM.
The overview indicates that CIROS Advanced Mechatronics is
connected to
S7 PLCSim via the virtual controller of EzOPC. The table shows which
components are installed individually and whether EzOPC is in the
process of accessing this component.
Make sure that the communication links of your EzOPC are
configured as shown below. The desired communication links are
established by clicking onto the appropriate button.

15. Now click onto the Virtual Controller register where the virtual
controller status and your inputs/outputs are displayed. 8 input
bytes and 8 output bytes are preset for data exchange. You can
accept this presetting unaltered.
If a 1-signal is applied to an input/output byte bit, then this is shown
illuminated.

16. Click onto the S7-PLCSIM register and check the settings. Here, the
status of S7-PLCSim simulation and its inputs/outputs is displayed.
8 input bytes and 8 output bytes are preset for data exchange. You
can accept this presetting unaltered. However, only the first 4 bytes
are required.
If a 1-signal is applied to an input/output byte bit, then this is shown
illuminated.
17. Minimise the EzOPC window.

18. Start S7-PLCSIM by clicking onto the check box next to RUN in the
CPU window. The LED for RUN should now start flashing.

19. Operate the system. In particular, observe the behaviour of those

stations for which you have created the PLC program yourself. It can
be useful here to monitor the statuses of the PLC inputs and outputs
for the respective station.
Open the Inputs and Outputs window by activating the commands
Show Inputs or Show Outputs under the Inputs/Outputs entry in
the View menu.

20. Make sure that the PLC inputs and outputs for the right station are
displayed by activating the Controller Selection command in the
Programming menu. Select the controller for the desired station in
the Current column. For the example this should be the distributing
station.

21. If errors still exist in the PLC program, then the online representation
in STEP 7 provides excellent support during fault finding. To do so,
call up the program module in which you suspect the fault. Activate
the Monitor command in the Test menu. You can now monitor which
PLC program sections are executed or not in parallel with the
simulation of the process.

4.12 CoDeSys SP PLCWinNT is a Soft PLC which executes the PLC programs
Controlling a station of created in CoDeSys.
the system using the
external Soft PLC The PLC input and output signals are exchanged between the system
CoDeSys SP PLCWinNT simulation and the Soft PLC CoDeSys SP PLCWinNT via the EzOPC
program. EzOPC is part of the CIROS Automation Suite, and will have
been installed on your PC together with the CIROS Advanced
Mechatronics application.
CIROS Advanced Mechatronics automatically starts up EzOPC as soon

as the simulation of the system begins. Of course, at least one station of
the system must be under the control of an external PLC before EzOPC
can be started.
Note If you are using the MS Windows Vista operating system, ensure that
the version of CoDeSys SP PLCWinNT which you are using is Vista-
compatible.

The following requirements must be fulfilled in order to ensure that the

PLC input and output signals are exchanged correctly with the selected
station:
There must be an interface to the OPC server EzOPC in the CoDeSys
PLC program. The input and output signals of the PLC program are
transferred byte by byte via this interface.
The UNPACK functional module and the PACK function in CoDeSys
can be used to convert bits to bytes.
Program execution in CoDeSys SP PLCWinNT
UNPACK (FB) PLC program PACK (FUN)

EB0 OPC_notUsed OPC_notUsed AB1
B B0 B0 PACK
OPC_1B2 OPC_P2
B1 OPC_1B2 & OPC_P2 B1
OPC_notUsed OPC_notUsed
B2 OPC_2B1 B2
OPC_2B1 OPC_notUsed
B3 OPC_3B1 B3
OPC_3B1 OPC_notUsed
B4 B4
B5 B5
B6 B6
B7 B7
EzOPC
Process inputs Process outputs

(Sensors) (Actors)
CIROS
Process model
simulation
Simple program example of OPC interface in CoDeSys

When starting EzOPC, both communication users CoDeSys SP

PLCWinNT and the system simulation in CIROS must already be
active. Only then can EzOPC set up the communication link to both
users.
The EzOPC program must be correctly configured for data exchange.
In order to ensure this, check the configuration as soon as EzOPC
starts up.
Configuration of EzOPC for data exchange with S7-PLCSIM

This is how you control a station of the virtual system with

CoDeSys SP PLCWinNT
1. Start CoDeSys and open the desired CoDeSys project.

2. Make sure that the Util.lib library is entered in the Resources tab.
If this is not the case, add the Util.lib library using the Library
Manager: Double-click on Library Manager in the Resources tab. In
the Insert menu, select Additional Library. Find the location where
Util.lib is stored. The default location for the library is in the
directory c:\Program Files\3S Software\CoDeSys\Library.
Once you have selected the Util.lib library, click on the Open button.
Close the Library Manager window.
3. Next, define the input/output signals to be exchanged with the
CIROS process model via the OPC interface. The input/output
signals in the example project can be easily identified by the
extension OPC. The input/output signals are defined as global
variables.
You can open the Global_Variables window by opening the Global
Variables folder in the Resources tab, then double-clicking on
Global_Variables.

4. Expand the control program by calling up the UNPACK functional

module. This extracts the EB0 input byte and converts it into
8 Boolean variables. In the example project, only bits 1, 3 and 4 of
the EB0 input byte are needed.
Remember that an instance (Unpack_EB0 in the example) must be
defined in the program head before a functional module can be
called up.
5. Expand the control program by calling up the PACK function. The
PACK function combines 8 Boolean variables into one byte. In the
example, the PACK function shows the output signal OPC_P2 on bit
1 of output byte AB1.

6. Make sure that the Soft PLC CoDeSys SP PLCWinNT is set as the
target system for the project. To do this, double-click on Target
Settings in the Resources tab. 3S CoDeSys SP PLCWinNT must be
set as the configuration.
7. Next, configure the settings in CoDeSys for the data exchange

between CoDeSys SP PLCWinNT and CIROS Advanced
Mechatronics. To do this, open the Start menu, go to
3S Software -> Communication and select CoDeSys OPC
Configurator.

8. Set Single PLC for OPC communication. Do this by selecting Single

PLC in the File menu.
9. In the tree structure, click on Server and set an Update Rate of 100
for the OPC server. Alternatively, you can also use the preset value.

10. In the tree structure, click on PLC and enter the name of the PLC
project.
Note
The project name must exactly match the name of the CoDeSys
project file. If the project is changed, the name must also be
changed here to match.

11. In the tree structure, click on Connection to specify the type of

connection between the OPC server and the Soft PLC. As both
programs run on the same computer, select the Local option for
Gateway. Select Tcp/lp with the Address localhost as the Device for
the new connection.
Configure the settings in the Communication Parameters window.
12. Open the Communication Parameters window by clicking on the

Edit button. Then click on the Gateway button and select Local as
the connection for Gateway.

13. Click the New button to define the parameters for the new
connection channel. Enter the name of the channel and select
Tcp/lp as the device.
14. Close the window Communication Parameters: New Channel.

15. Close the windows Communication Parameters and OPCConfig.

16. Next, prepare the input/output bytes which are to be transferred via
the OPC interface for data exchange. To do this, activate the Options
command in the Project menu in CoDeSys. In the Options window,
click on Symbol configuration.

17. Select Dump symbol entries, then click on the configure symbol file
button.
This opens the Set object attributes window.

18. Open the Global Variables folder and select the objects AB1 (BYTE)
and EB0 (BYTE). Hold down the Ctrl key while selecting.
Place a tick in each check box and close the Set object attributes
and Options windows.
19. Click on the Rebuild all command in the Project menu.

20. Start CoDeSys SP PLCWinNT by selecting it from the Start menu.

21. The CoDeSys SP PLCWinNT window opens.
22. To establish the connection between the CoDeSys programming

system and the Soft PLC CoDeSys SP PLCWinNT, activate the Login
command in the Online menu in CoDeSys.

23. If the current project is different to the PLC program in the Soft PLC,
you will be asked whether you wish to load the current PLC program
when you log in. Click Yes.
The current project is loaded into the Soft PLC.

24. Load the corresponding MPS in CIROS Mechatronics.
25. Alter the settings for the desired station so it is controlled by an

external PLC. To do this, go to the Modeling menu and activate the
Switch external PLC internal PLC command.

26. The Switch external PLC internal PLC window opens.

The Type and Program Name/OPC Server columns show
information on how the selected station is controlled.
For example, take a look at the entries for the Distributing station:
The name of the station is S7_Distributing.
The station is controlled by the internal PLC. You can see this
from the S7 PLC Simulator entry in the Type column.
The internal PLC executes a PLC program. The PLC program is
part of the STEP 7 project MPSC_V22.S7P with the specified
path.
27. Click on the desired station to highlight it. Click the right mouse
mutton to open the context-sensitive menu. Select the Switch
command.
Alternatively, you can switch the control system by double-clicking
on the desired station.

28. The column Type now shows OPC Server for the selected station.
The Program Name/OPC Server column now shows the server name
FestoDidactic.EzOPC.2. This means that the process signals for the
selected station are exchanged via an OPC server with the name
FestoDidactic.EzOPC.2.

30. Check whether the system is meant to be in the basic setting. If so,
activate the Reset Workcell order in the Simulation menu.

31. Start the simulation of the system. To do this, open the Simulation
menu and select Start.
As the simulation starts, the EzOPC program is automatically
opened. You can see this because EzOPC appears in the start bar.
Note When the system simulation starts, the EzOPC communication program
also starts up. When starting EzOPC, both communication users
CoDeSys SP PLCWinNT and the system simulation must already be
active. Only if this is the case will the communication links be correctly
set up.

32. Click on the EzOPC button in the Start bar. The EzOPC window
opens. Here you can configure the communication between CIROS
Advanced Mechatronics and CoDeSys SP PLCWinNT.
The overview shows that CIROS Advanced Mechatronics is
connected to CoDeSys SP PLCWinNT via the EzOPC virtual control
system. The table shows details of which components are installed
whether EzOPC directly accesses these components.
Make sure that the communication links of your EzOPC are
configured as shown below. You can create the desired
communication link by clicking the corresponding button.

33. Next, click on the Virtual Controller tab. This displays the status of
the virtual controller and its I/Os. 8 input bytes and 8 output bytes
are preset for data exchange. You can use this preset without
modifying it.
If logic 1 applies to any bit of the input/output byte, this bit is
represented by a brighter colour.

34. Click on the CoDeSys tab and check the settings. This tab shows the
status of the CoDeSys SP PLCWinNT simulation and its inputs/
outputs. 8 input bytes and 8 output bytes are preset for data
exchange. You can use this preset without modifying it. However,
only the first 4 bytes are required.
If logic 1 applies to any bit of the input/output byte, this bit is
represented by a brighter colour.

36. Make sure that the process model simulation is active in CIROS

37. Start running the PLC program in the Soft PLC. To do this, open the
Online menu and click Run.
You can see the current status of the Soft PLC CoDeSys SP PLCWinNT
in the CoDeSys SP PLCWinNT window.

38. Operate the system. Pay particular attention to the behaviour of the
station to which you have added the PLC program yourself. You
might find it helpful to follow the statuses of the PLC inputs and
outputs for the station in question.
To open the Inputs and Outputs windows, go to the View menu,
select Inputs/Outputs and activate the Show Inputs and
Show Outputs commands.

39. Make sure that the PLC inputs and outputs are shown to the right
station. To do this, go to the Programming menu and activate the
Controller selection command. Select the control system for the
desired station in the Current column. In the example, this would be
the Distributing station.

4.13 If you are creating and testing your own PLC programs we recommend
Controlling a station of that you load the programs to an external PLC and execute them from
the system using an there.
external PLC
If you are programming in STEP 7, you can use the soft PLC S7-PLCSIM
as PLC, in which case you will not require any additional hardware
components.
You can however also use any other control and programming system,
in which case you load the PLC program to your hardware PLC. The PLC
program is to control a selected station of your virtual system.
The exchange of PLC input/output signals between the system
simulation and your external PLC is effected via the serial or the USB
interface of the PC and via the EasyPort interface. In addition the EzOPC
program is involved in the exchange of process signals.
The advantage of this configuration is that you can use the PLC and the
programming system of your choice. Also the testing and diagnostic
functions provided by the programming system for this purpose are
available to you for fault finding in the PLC program.
We recommend that you install the simulation software CIROS

Advanced Mechatronics and the PLC programming system on different
computers.

EasyPort
PLC
Possible configuration with hardware PLC and two PCs

You can however also select another configuration and install the two
software packages on one PC. Your PC needs to be equipped with two
serial interfaces or one serial and one USB interfaces if you want to use
the testing and diagnostic functions of the programming system during
simulation of the virtual system.
You can use the following as EasyPort interface:

EasyPort D16 interface box for 16 digital I/O (Pt. No. 167121)
The following is required as data cable:

PC data cable RS232 for EasyPort with PC to RS232 (Order No.
162305) or
USB adapter RS232 for EasyPort with PC on USB (Order No. 540699)
For PLC EduTrainer from Festo Didactic: I/O data cable with SysLink
connectors to IEEE 488 at both ends (Pt. No. 034 031) and adapter
for extension to IEEE 488, crossover (Pt. No. 167 197)
For any PLC: I/O data cable with SysLink connector to IEEE 488 at
one end and open cable end sleeves (Pt. No. 167 122)
Note If you want to exchange signals of one or more than 16 process

inputs/outputs between an external PLC and a virtual system in CIROS
Advanced Mechatronics, you will need two or more EasyPort interfaces.
The EzOPC program The EzOPC program organises the exchange of PLC input/output signals
between the virtual system simulation and the external PLC. EzOPC
does not access the signals of the external PLC directly but via the
EasyPort interface.
The EzOPC program forms part of the CIROS Automation Suite and has
been installed on your PC in conjunction with the CIROS Advanced
Mechatronics application. EzOPC is automatically invoked by CIROS
Advanced Mechatronics as soon as simulation of the system starts.
Prerequisite for starting EzOPC is of course that at least one station of
the system is controlled via an external PLC.

The following requirements must be fulfilled to ensure that the

exchange of PLC input/output signals with the selected station is
correct:
When starting EzOPC, both communication users EasyPort and
simulation of the system must be active. Only then can EzOPC set
up the communication link with the two users.
In the case of EasyPort this means that EasyPort must be connected
to the PC via the serial or the USB interface and voltage must be
applied to EasyPort.
The EzOPC must be correctly configured for the exchange of data.
Therefore check the configuration as soon as EzOPC is started.
Configuration of EzOPC for data exchange with an external PLC via EasyPort

This is how you control a station of a virtual system using an external

PLC
1. Load the desired PLC program to the external PLC. The external PLC
is in the STOP operating status.
2. Connect the PC with CIROS Advanced Mechatronics to the external
PLC via the EasyPort interface.
The data cable Pt. No. 162 305 connects the serial interface of
the PC to the serial interface RS232 of EasyPort.
If you are using the USB interface, then use the data cable of
Order No. 540699.
The PLC input output signals for the process are applied at port 1
of EasyPort.
The PLC input/output signals for the control console are
transmitted via port 2.
If you are using EasyPort without USB interface:
Select the following setting for the DIP switches under Mode on
EasyPort:
1 ON (bottom), 2 OFF, 3 OFF.
If you are using EasyPort with USB interface:
Make sure that address 1 is set for EasyPort.
The set address can be read or changed by pressing the two
arrow buttons. Simultaneously pressing both buttons stores the
address and exits address mode.

Process model
1 2 3
ON
S7 EduTrainer EasyPort
RING IN OUT MODE RS232 - 24V +
CPU313C-2 DP CP 343-2
SF SF
BF 0 0 PWR
DC5V 1 1 APF
FRCE 2 2 CER
RUN 3 3 AUP
STOP 4 4 CM
PUSH
5 5 EasyPort D16
6 6 B
RUN
7 7 20+
STOP
MRES 10+
IN OUT SET
A STATUS SHORT
9
0 0 8
1 1 7 INPUT
2 2 6 OUTPUT
3 3 5 0 7 8 15
4 4 4
5 5 3
6 6 2
7 7 1
0 PORT 1 PORT 2
B
3
1
Configuration with PLC EduTrainer
Note The two sockets marked EMERGENCY-STOP must be bridged so that the
output modules of the PLC receive the voltage supply.

Process model
1 2 3
ON
EasyPort
RING IN OUT MODE RS232 - 24V +
EasyPort D16
STATUS SHORT
INPUT
OUTPUT
0 7 8 15
PORT 1 PORT 2
XMA2 XMG1
PLC board
Configuration with PLC board

3. Switch on the voltage supply of EasyPort. Note that EasyPort can

receive voltage supply via the PORTS.
4. Load the desired system in CIROS Advanced Mechatronics. One
station of the system is to be controlled via an external PLC. The
distributing station has been selected in the example.
5. Effect the setting for the required station which is to be controlled

via an external PLC by activating the Switch external PLC internal
PLC command in the Modeling menu.

6. This opens the Switch external PLC internal PLC window.

The controller for the selected station is shown in the columns Type
and Program name/OPC Server.
As an example take a look at the entries for the distributing station:
The name of the station is Distributing.
The station is controlled via the internal PLC. You can establish
this by the entry S7 SPS Simulator.
The internal PLC executes the PLC program. The PLC program
forms part of the STEP 7 project MPSC_V22.S7P with the path
indicated.
7. Highlight the required station via a mouse click. Activate the context
sensitive menu via the right mouse button and select the Switch
command.
Alternatively changeover the controller by clicking onto the required
station.

8. OPC Server is entered for the selected station in the Type column.
FestoDidactic.EzOPC.2 is shown under Program name/OPC Server.
This means that the process signals for the selected station are
exchanged via an OPC server named FestoDidactic.EzOPC.2.

10. Check whether the system is to be in the initial position. If so,
activate the Reset Workcell command in the Simulation menu.

11. Start the system simulation by activating Start in the Simulation

menu.
With the starting of simulation, the EzOPC program is automatically
invoked. You can establish this by the EzOPC entry in the start bar.

Note With system simulation starting, the communication program EzOPC is

also started. When EzOPC is started, both communication users
EasyPort and the simulation of the system must already be active.
Only then are the communication links correctly set up.
12. Click onto EzOPC in the start bar to open the EzOPC window. Here
you configure the communication between H CIROS Advanced
Mechatronics and EasyPort.

13. The overview shows that CIROS Advanced Mechatronics is

connected to S7 PLCSim via the virtual controller of EzOPC.
You will need a communication link between CIROS Advanced
Mechatronics and EasyPort. Click onto the PLC via EasyPort button
to establish this.

14. The configuration link between CIROS Advanced Mechatronics and

EasyPort is configured.
The table indicates which components are installed and whether
EzOPC is currently accessing these components.

15. Now check the range of inputs/outputs via which data exchange is
to be effected in the virtual controller. To do so, click onto the
Virtual Controller register.
8 input bytes and 8 output bytes are preset for data exchange. You
can accept these presettings unaltered. Only the first 4 bytes are
required.

16. Click onto the EasyPort register where the status of the connected
EasyPort and its inputs and outputs are displayed. If a 1-signal is
applied to an input/output byte bit, then this is shown illuminated.

18. Make sure that the required PLC program is installed in the PLC.
19. Start the PLC.

20. Operate the system and in particular observe the behaviour of the
station for which you have created the PLC program, whereby it may
be helpful to observe the statuses of the PLC inputs and outputs of
the relevant station. Open the inputs and outputs window by
activating the Show Inputs/Show Outputs command under the
Inputs/Outputs entry in the View menu.

21. Make sure that the PLC inputs and outputs for the right station are
displayed. Activate the Controller Selection command in the
Programming menu and select the controller for the desired station.

4.14 Use the Fault Setting window to set specific faults in the functional
Setting faults in a system sequence of a system. Use the internal S7 PLC and the sample PLC
programs provided to control the system. This ensures that any
potential process malfunction is caused solely by the process
components. The PLC programs operate error-free.
The setting of faults is permissible for authorised persons only and the
dialog for the setting of faults is therefore password protected.
The default setting for the password is didactic. This password can be
changed at any time.
A list of possible faults is available for each modelled system. The

entries for the individual stations are arranged in a tree structure. All
entries for the relevant station are displayed by double clicking onto the
+ symbol of a station. To hide the entries again double click the minus
symbol.

The following data is required if you want to create a fault in the case of
one of the listed process components:
Type of fault,
Start of malfunction,
Duration of malfunction.
Various faults can occur in the case of some components. You can select
these in a selection list.
The following denote:

Reed switch misaligned: Reed switch is mechanically misaligned.
Reed switch stuck: A 1 signal is permanently applied at the reed
switch.
Cable break: A 0 signal is permanently applied at the component.
Short circuit: A 1 signal is permanently applied at the component.
Failure: Complete component failure.
Tubing faulty: Pneumatic tubing is defective, operating pressure is
not achieved.
Compressed air line faulty: No compressed air available.
Voltage supply malfunctioning: No voltage.
The time specified for the commencement of malfunction refers to the

simulation period after the fault is set.
The duration of malfunction is to be specified in seconds.
The error statuses are effected in the simulation of the modelled system
as soon as the fault simulation is active.
If you exit and restart CIROS Advanced Mechatronics, malfunction still

remains active and remains active until it is deactivated in the Fault
Setting window.
Note Default malfunction however only becomes active if the fault simulation
mode is activated.

This is how you set faults in a modelled system
1. Make sure that the system is loaded. The system is to be controlled

via the internal PLC. Simulation is not active.
2. Open the Fault Setting window by activating the Fault Setting entry
in the Extras menu under Fault Simulation.

3. The dialog for the password entry is now displayed.

Enter the password. Provided that you have not changed the
password since installing CIROS Advanced Mechatronics, the set
default password is still valid.
Under password, enter didactic
Please note that the above password is case sensitive.
Confirm the entry with OK.
4. The Fault Setting window now opens.
5. Double click the + symbol of for example the distributing station to

display all the possible faults of this station.

6. Now set a malfunction for example for the PLC input 1B1.
Double click the appropriate field in the Type column. A selection list
is displayed. Open this list and select the type of fault, for example
cable break.
The fault is to become active at the start of simulation and remain
active until the fault is removed from the fault setting. No entries are
therefore required in the Begin column.
The duration of the fault is arbitrary. No entries are therefore
required in the Duration column.

7. The faults selected are displayed in the Status column.
8. Close the file of the modelled system in order to deactivate the

teacher mode.
9. Load the system with the set faults.

10. Now activate the fault simulation mode by selecting Fault

Simulation in the Extras menu under Fault Simulation.

This is how you start simulation of the system with set faults
1. Load the system with the set faults.

2. Make sure that the fault simulation mode is activated. The menu
item Fault Simulation in the Extras menu under Fault Simulation
must be ticked.
3. Start simulation of the system.

4.15 Use the Fault Localisation window to eliminate malfunction in the

Eliminating faults in a functional sequence of the system. Set malfunction only occurs if the
system system is controlled via PLC programs and if the fault simulation mode
is active.
Example The MPS system viewed consists of the distributing, testing and sorting
stations. The sequence of the system stops once a workpiece is ejected
at the distributing station. The next step - moving the swivel arm into
the magazine position - is not executed.
By observing and evaluating the system, you realise that voltage is
applied at sensor 1B1 of the distributing station, but not at the
corresponding PLC input. You therefore conclude a cable break at the
PLC input 1B1.

This is how you eliminate faults in the system
1. Make sure that the desired system is loaded.

2. Open the Fault Localisation window by clicking onto Fault
Localisation in the Execute menu.

3. The Fault Localisation window is now displayed.
4. Double click the + symbol of the distributing station to view all

possible faults.

5. Double click no fault in the line PLC input 1B1 and select cable
break from the selection list.
The button is illuminated in yellow.
If the fault has been identified correctly, the distributing station
sequence will be executed error-free in the next simulation cycle.

6. In the teacher mode, the Fault Localisation window is displayed as

follows:
Note If you have correctly identified and entered the fault, the sequence
of the system will be executed error-free in the next simulation cycle.
If the cause of the fault has not been identified correctly, the fault
will continue to exist.
If you have erroneously identified and entered the cause of the fault
as a mechanically misaligned sensor, you have created an additional
fault in the process. The fault is active as of the next simulation
cycle.

4.16 Each action in the Fault Localisation window is recorded in a log file.
Logging error elimination Authorised persons have the option of viewing the log file.
The log file contains a list of activities carried out in the fault localisation
window. The entries contain the following data
Date
Time
Correctly identified and eliminated faults are highlighted in green.

This is how you view the log file
1. Open the fault log window by activating the Fault Log entry in the
Extras menu under Fault Simulation.
2. The dialog box for the password entry is now displayed.
Enter the password. The preset default password is still valid,
provided that you have not changed this since installing CIROS
Enter didactic under password.
Note that the password is case sensitive.
Confirm your entry with OK.
3. The Fault Log window is now displayed.
Note If you want to delete the fault log, activate the context-sensitive menu
via the right mouse button and select the appropriate command.

5. These training contents can be taught using
CIROS Advanced Mechatronics
CIROS Advanced Mechatronics is a multimedia training aid dealing

with the subject of automated systems. The examples used relate to
practical applications in industry and the problem definitions are based
on industrial handling sequences and are aimed at a holistic training
process. With CIROS Advanced Mechatronics you are imparting
methodological and handling competence.
5.1 CIROS Advanced Mechatronics provides process models for different,

Training contents and complex sections of production systems.
training aims
Main training aims The general training aims of CIROS Advanced Mechatronics are to
achieve the following skills
To design and construct PLC controlled systems in the form of
distributed systems,
To specify, design and test communication between the intelligent
stations of a distributed system,
To create, modify and test the PLC programs for the individual
stations of a distributed system or complete system,
To carry out systematic fault finding as part of servicing and
maintenance of distributed systems.
This training aim deals with all the topics which can be addressed by
means of simulated processes of distributed systems. The main focus of
training is aimed at a methodical procedure.

5. These training contents can be taught using CIROS Advanced Mechatronics
General training aims The following general training aims can be derived from the main
training aims:
The user designs a production process in the form of a distributed
process and creates the appropriate system.
The user understands "intelligent units" as re-usable technological
modules, whereby certain specific control functions are realised.
The user selects a transport system for a system and integrates this
into the system.
The user familiarises himself/herself with preassembled MPS
standard or MPS 500-FMS systems and understands their design
and mode of operation.
The user familiarises himself/herself with component based
automation (object-oriented procedure during the design and
construction of a system) in practice and uses this.
The user specifies the communication interface between the
different "intelligent units" of a distributed system.
The user designs the communication of a distributed system.
The user designs, modifies and tests PLC programs for individual
"intelligent units".
The user practises structured and modular PLC programming.
The user transmits communication information to the PLC program
in the form of parameters via an interface.
The user incorporates, tests and observes communication
information in the PLC programs of the "intelligent units".
The user locates and eliminates faults in the individual "intelligent
units".
The user carries out systematic fault finding in complex systems.

Significance of training Industrial development over the last few years has been governed by an
contents in industrial ever increasing degree of automation, more and more complex work
practice processes and faster operational sequences. The keywords here are
optimal utilisation of high investment, flexible and cost effective
production. These include:
High machine efficiency,
Reduction in downtimes,
Modularisation of systems and distributed intelligence,
Optimisation of systems,
Continual improvement processes.
As a result of the above, completely new requirements need to be met

to some extent by all those in direct contact with a system. Operators
and fitters assume small maintenance tasks and eventual repairs.
Maintenance technicians must be able to understand electrical and
electronic control technology up to a certain level to be in a position to
reach conclusions regarding mechanics, pneumatics and hydraulics.
Conversely, electrical engineers require knowledge regarding
pneumatic and hydraulic actuators. These changing requirements in
turn also lead to new forms of collaboration.
By classifying these necessary requirements, the following areas are

created
Technology know-how
System know-how and understanding
Sociocultural skills
CIROS Advanced Mechatronics enables you to develop know-how and

learn skills in the areas of technology know-how and system know-how
and understanding. Apart from technical knowledge, these skills also
include handling and methodological competence.

5.2 The target group for CIROS Advanced Mechatronics includes all those
Target group whose vocational line of activity involves networking, PLC programming
and the maintenance and servicing of networked systems or who
require basic knowledge of these subjects.
These include:
Vocational training
Mechatronic engineers
Electronics engineers, for example specialising in automation
technology
Plant electronics engineers
Industrial mechanics
Specialist qualification in the metal and electrical engineering field
Training at technical colleges and universities
5.3 The following prior knowledge is required for training and working with
Prior knowledge CIROS Advanced Mechatronics:
Basic knowledge of control technology: Structure of an automated
system
Basic knowledge of PLC technology: Design and mode of operation
of a PLC
Basic knowledge of PLC programming and handling of a PLC
programming tool such as the programming system SIMATIC STEP 7
Basic knowledge of pneumatic control technology: Drives, control
elements
Basic knowledge of sensor technology: Limit switches, contactlessly
operating proximity sensors
Basic knowledge of design, wiring and tubing up of
electropneumatic systems.
Basic knowledge of electrotechnology: Electrical variables, the
correlation and calculation thereof, DC and AC current, electrical
measuring techniques
Basic knowledge of how to read and interpret circuit diagrams
Skills in dealing with and operating Windows programs

5.4 Below is a table of training aims on the subjects of system know-how,

Example: Allocation of PLC programming, communication and systematic fault finding. The
training aims to syllabi training aims are taken from the vocational training syllabus for
mechatronics engineers, status 1999. The contents are correspondingly
adapted and weighted, for example in the syllabi for electrical and
electronics engineers, status 2003.
The skilled trades of mechatronics or electronics engineers are two
examples of how, in Germany, skilled trades are currently updated and
adapted to the concept of new training areas.
The tables only lists those training aims which form part of CIROS
Advanced Mechatronics training.

Training content: Analysis of mode of operation and structure of a system
Vocation Training area Training aim
Mechatronics Training area 1: Reading and using technical documentation.

engineer Analysing of functional
Mastering the procedure for analysing and documenting
correlations in
functional correlations.
mechatronic systems
Designing and interpreting block diagrams.
Reading signal flow, material flow and energy flow with

the help of technical documentation.
Training area 4: Reading basic circuits of control technology: Actuation

Examining energy and (pneumatic and hydraulic) of a single-acting and double-
information flow in acting cylinder, basic logic operations, protective circuits,
electrical, pneumatic digital circuits.
and hydraulic modules
Reading and using circuit diagrams.
Familiarisation with supply units in electrics, pneumatics

and hydraulics.
Understanding and describing the control functions of

simple control systems.
Configuring a control system (block diagram).
Understanding signals and measured values in control

systems.
Training area 7: Understanding and describing the structure of

Realising mechatronic mechatronic subsystems.
subsystems
Understanding and evaluating the mode of operation,
signal behaviour and use of components (sensors and
actuators).
Understanding basic circuits and the mode of operation

of drives.

Training content: Analysis of mode of operation and structure of a system
Vocation Training area Training aim
Training area 8: Describing the structure and signal characteristics of a

Design and mechatronic system.
construction of a
Analysing the effect of changing operating conditions on
mechatronic system
the process sequence.
Training area 9: Describing the information structure (signal structure,

To examine the signal generation, signal transport) of a system.
information flow in
Setting up the connection between electrical,
complex mechatronic
mechanical, pneumatic and hydraulic components.
systems
Analysing signals (binary, analogue, digital) and
establishing possible error sources.
Using computer-aided diagnostic methods such as

testing and diagnostic functions of the programming
system or bus system.
Training area 11: Analysing mechatronic systems on the basis of technical

Commissioning, fault documentation and separating the construction into
finding and repairs function blocks.
Training area 13: Describing a mechatronic system.

Handover of
Drawing up operating instructions and documentation.
mechatronic systems
to customers

Training contents: PLC programming and testing of the program
Profession Training area Training aim
Mechatronics Training area 7: Understanding the design and mode of operation of a

engineer Realising mechatronic PLC.
subsystems
Designing and documenting control systems for simple
applications. Programming simple control processes
using a PLC: Logic operations, memory functions, timers,
counters.
Realising the programming in one of the PLC

programming languages: Ladder diagram or statement
list to DIN EN 61131-3.
Documenting control systems in function diagrams and

function chart to DIN EN 60848.
Training area 8: Programming of mechatronic systems in one of the

Design and programming languages: Ladder diagram, function chart,
construction of statement list, sequence language.
mechatronic systems
Programming operating mode sections.
Programming a sequence control.
Training area 9: Using computer-aided diagnostic methods such as

Examining the testing diagnostic functions of the programming system.
information flow in
complex mechatronic
systems
Training area 11: Eliminating errors in the PLC program.

Commissioning, fault
finding and repairs

Training contents: Communication within a system
Profession Training area Training aims
Mechatronics Training area 9: Describing the information structure of a system with the
engineer Examining the help of circuit diagrams and technical documentation.
information flow in
Analysing signals and establishing possible error
complex mechatronic
sources.
systems
Measuring and detecting signal faults in bus systems.
Understanding and realising the networking of

subsystems.
Understanding hierarchies of networked systems.
Using computer-aided diagnostic methods such as

testing and diagnostic functions of the programming
system.
Incorporating changes into existing documentation.

Training content: Systematic fault finding in systems
Profession Training area Training aim
Mechatronics Training area 4: Fault finding on simple modules with the help of
engineer Examining the energy measuring technology.
and information flow in
electrical, pneumatic
and hydraulic modules
Training area 7: Testing control systems for simple applications, e.g. by

Realising mechatronic means of signal analysis.
subsystems
Training area 8: Identifying faults by means of signal analysis at

Design and interfaces, eliminating error causes.
construction of
Computer simulation
mechatronic systems
Training area 9: Analysing signals (binary, analogue, digital) and

Examining the establishing possible error sources.
information flow in
Using computer-aided diagnostic methods, e.g. testing
complex mechatronic
and diagnostic functions of the programming system.
systems
Training area 11: Understanding procedures for fault finding in electrical,

Commissioning, fault pneumatic and hydraulic systems.
finding and repairs
Carrying out malfunction analysis. Mastering and using
systematic fault finding.
Knowing typical error causes.
Targeted use of diagnostic systems.
Documentating faults.
Drawing up a maintenance and repairs protocol.

5.5 CIROS Advanced Mechatronics is a motivating, multimedia training aid

The training concept of on the subject of automated systems.
CIROS Advanced
Mechatronics The systems can be flexibly programmed to different levels of
complexity. This enables you to formulate problem definitions according
to the requirements and prior knowledge of trainees whereby, for
example, the mode of operation of individual components can be
examined. It is however also possible to concentrate on the subject and
training for planning the communication in a distributed system or
programming and testing the operating mode part of a system.
The simulated processes have their own didactic quality:

They are as practice-related and real as possible.
The possibility of experimenting with process models establishes an
affective link to actual systems, i.e. the actual training topic, thereby
testing and consolidating knowledge.
The realistic experience with simulated processes provides a new
quality of knowledge: Theoretical knowledge becomes application
and practice-oriented ability.
CIROS Advanced Mechatronics supports self-motivated and enquiring

learning:
The simulated system functions in the same way as an actual
system. For example, this immediately shows trainees whether they
have programmed the system sequence correctly. Similarly the
effect of operational errors is apparent without causing damage to
the system. This enables trainees to reach and evaluate conclusions.
Trainees can obtain technical documentation regarding the system
or system components according to requirement.
Trainees can practise their know-how and skills on a wide variety of
systems.

What are the benefits of tuition using CIROS Advanced Mechatronics?

CIROS Advanced Mechatronics is a PC-assisted training aid and
therefore represents a different training method. Lessons can be
made stimulating and motivating.
Know-how and skills acquired on actual systems can be improved
and consolidated using practice-related process models.
Simulated processes can be used to illustrate and test situations
which would be dangerous on an actual system.
Efficient, practice-related and task oriented training is possible even
without an actual system.
A system, available only once in reality, is available in multiple
forms. This increases the availability of the system for tuition.
The real and virtual world of automation technology can be
combined in any way and adapted to the training process required.
All systems simulated in CIROS Advanced Mechatronics are also
available in the form of actual systems. This provides ideal additions
and combinations for tuition.
Activities and skills which can only be acquired on actual systems
should not be replaced but merely supplemented, prepared or dealt
with more extensively.
Simulation is a modern tool used in dealing with automated
systems.
Example 1: To ensure that PLC programs and the design of a system
are completed at the same time, appropriate simulation of system
components or of the complete system is used to test the PLC
program.
Example 2: Since production systems should have as few
downtimes as possible, operators and maintenance staff are often
familiarised with and trained on simulated systems.

5.6 CIROS Advanced Mechatronics can be used in many different ways for
Training scenarios for vocational and further training. Here are a few examples:
CIROS Advanced CIROS Advanced Mechatronics in the form of an introduction for
Mechatronics the purpose of motivation, preparation and as a knowledge
database for actual MPS systems:
The user has an actual MPS system which he/she wants to
understand and operate.
With CIROS Advanced Mechatronics users have the possibility of
creating their actual MPS system in the form of a virtual system.
With the help of this virtual system, users can familiarise themselves
with the automation components and stations of their system.
Information is available on the online Help and via an online
Assistant. Since the control and communication of the system can
be automatically generated, the user does not require any
knowledge of PLC programming and networking of systems for this
phase. System production can be immediately simulated and the
behaviour of the system observed. In line with the users problem
definition, one can acquire comprehensive basic knowledge
regarding electrical and pneumatic processes and the components
involved or practise and improve the programming of distributed
systems.
CIROS Advanced Mechatronics in the form of an introduction for
the purpose of motivation and preparation on the subject of
distributed automation systems:
CIROS Advanced Mechatronics can be used independently of
actual systems. On the basis of a library with automation stations,
the user plans and designs distributed systems of varying
complexity. Typical automation stations include warehouse
administration, robots, processing machines and transport systems.
Information regarding the components and stations is available to
the user on the online Help and via an online Assistant. Since the
control and communication of the system can be automatically
generated, the user does not require any knowledge of PLC
programming and networking of systems. The sequence of the
system can be simulated immediately and the behaviour of the
system observed.

In line with the users problem definition, one can acquire

comprehensive basic knowledge regarding electrical and pneumatic
processes and the components involved, gain an understanding of
distributed processes and practise and improve the programming of
a distributed system.CIROS Advanced Mechatronics as a tool for
practising PLC programming in applications of varying complexity:
CIROS Advanced Mechatronics can be used independently of
actual systems. On the basis of two libraries with automation
stations, the user plans and creates simple or complex virtual
systems. If the user has prior knowledge in PLC programming,
he/she can change or completely recreate the PLC programs of the
individual stations. As soon as the desired PLC program is available,
the user can simulate the running of the system. Via the simulation,
the user immediately receives feedback as to whether the sequence
of the corresponding station has been correctly programmed. A
major advantage is that users can use the PLC and programming
system of their choice, whereby they have access to the testing and
diagnostic functions of the programming system. These permit quick
and effective fault finding and elimination in the generated PLC
program.
In the case of less practised PLC programmers, systems consisting
of one station can also be created. In this way all the training
contents for which only a single station is required can be taught in
CIROS Advanced Mechatronics.

CIROS Advanced Mechatronics as a tool for practising systematic

fault finding on systems of varying complexity:
With CIROS Advanced Mechatronics you can create systems of
varying complexity into which malfunctions can be incorporated. The
task of the trainee is to detect and eliminate the malfunctions during
the operation of a system.
CIROS Advanced Mechatronics supports you extensively during the
identification and evaluation of the ACTUAL status of the system:
process components. If compressed air is applied to a cylinder
connection, the connection is highlighted in blue. The statuses of
PLC inputs/outputs are shown in a separate window. By using a
nominal/actual comparison you can isolate the location of the fault
and a further systematic procedure enables you to find and
eliminate the fault.

6. This is how you create and operate a distributed
system in CIROS Advanced Mechatronics
CIROS Advanced Mechatronics supports you in a number of different

ways with the creation, familiarisation and analysing of distributed
systems.
The systematic procedure you use and the knowledge you acquire can
be used in any way you choose and of course also on actual systems.
A system is modelled from prepared stations. Whilst the system is

simulated, you can operate, observe and analyse it. The system
behaviour corresponds exactly to how this is defined in the PLC
programs provided for the individual stations. During simulation, the
PLC programs supplied are executed by the internal controller of each of
the stations. The PLC programs offer a possible sequence and possible
operation of the individual stations of the system. The stations can of
course also be controlled via other PLC programs created by the user.
6.1 The following training aims can be taught with the help of CIROS
Training aims Advanced Mechatronics:
Familiarisation with and understanding of the design and mode of
operation of a distributed system.
Familiarisation with typical components for the realisation of
automated systems: Sensors and limit switches, pneumatic valves,
pneumatic linear and rotary drives, electrical DC motors,
programmable logic controllers.
Modelling distributed systems from intelligent stations.
Operating and observing distributed systems.
Networking the stations of a distributed system.
Familiarisation with different production processes.
Evaluating technical documentation.
Researching information.
Recognising the advantage of a simulated system for industrial
operation.

6. This is how you create and operate a distributed system in CIROS Advanced Mechatronics
6.2 CIROS Advanced Mechatronics supports you with the following during
Support via CIROS the creation and familiarisation with distributed systems:
Advanced Mechatronics Library with prepared stations or station combinations. The stations
are intelligent, autonomous system sections which perform specific
machine functions.
Editor for the modelling of systems.
Simulation of the modelled system in 3D representation and the
execution of the sample PLC in the internal controllers of the
individual stations.
Windows for PLC inputs/outputs:
Status display of the PLC inputs/outputs of a station.
Manual Operation window:
Status display of all process sequences and statuses.
Manual Operation window:
Manual triggering of process sequences.
CIROS Advanced Mechatronics Assistant: Makes information
available online such as the description and circuit diagrams of
stations.
6.3
Example: Configuration of
a distributed system from
MPS Standard stations
and simulating production
Exercise Configure a system for the production of measuring instruments. The

workpiece housings for measuring instruments are to be supplied via
the handling station. After the assembly process, the produced
measuring instruments are to be sorted.
Answer the following questions:
Which stations do you require for the system?
In which sequence must be stations be arranged?
How is the initial position of the system defined?
Which workpieces are required for the production process?
How does the station react if a slide is filled with workpieces on the
sorting station.

Implementation 1. Start CIROS Advanced Mechatronics.

2. Activate the MPS System command under New in the File menu.
The Create MPS System window is now displayed.
3. Select a subdirectory for the new station as storage location. Enter
the file name. Select CIROS Workcells (*.mod).under file type.
Then click onto the Save button.

4. The model of an empty system is now displayed. When a new

system is created, a number of settings are carried out automatically
in CIROS Advanced Mechatronics:
The program changes into Edit Mode,
A table with possible workpieces is made available,
The Model Libraries window is opened.

5. Create the required system using the station models from the MPS
Stations Library. A brief description and preview of the individual
models is displayed if you highlight the library entry for the model
and then click onto the Details button.

6. You will find detailed information regarding the stations in the

library on the online Help in the chapter CIROS Advanced
Mechatronics. Start Help by activating the Examples and Models of
CIROS Advanced Mechatronics command in the Help menu. For
example a function description and technical documentation for the
station are offered.

7. Now check which station you need for the required system and how
the system is to be configured.
Result Your investigation shows that you will need the Pick & Place and Fluidic
Muscle press stations for the assembly process. In addition you will
also need the handling station adjusted for successor station and the
sorting station. The stations are placed directly next to one another and
are coupled via optical sensors.

8. Now create the system. First insert the handling station. To entries
are available to you for this station in the library. Since an additional
station will be added to the handling station, you require the
handling station adjusted for successor station. Highlight the
entry Handling Adjusted for Successor via a mouse click. Then
click the Add button.
The system now consists of the handling station adjusted for
successor station model. This station is shown in green since it is
still highlighted.

9. Simply click outside of the station if you want to cancel the

highlighting of the station.
A coupling point is shown on both sides of the station. This indicates
that the station can be connected to an additional station at this
point.

10. Now enter the Pick & Place station as an additional station.

11. All stations are inserted at the same position of the work space.
Move the newly added Pick & Place station by clicking onto the
highlighted station and moving the mouse pointer to the required
position whilst holding down the left mouse button.
12. The two models are positioned next to one another but are not yet
connected. To ensure that working and transfer positions coincide
during the production run of the system, both station models must
be correspondingly aligned and connected.

13. Now align the Pick & Place station model with the handling station
adJusted for successor station.
To do so, click onto the bottom grey shaded coupling point of the
Pick & Place station. Hold down the left mouse button and drag the
coupling point onto the coupling point of the handling station -
The Pick & Place station is now connected to the handling station

14. Now enter the Fluidic Muscle press station as the next station. This
station is also shown at the predefined point in the activity window.

15. Click onto the newly added, still highlighted station and move this
up next to the Pick & Place station.

16. Connect the Fluidic Muscle press station model to the upper, free
coupling point of the Pick & Place station model.
To do so click onto the lower, grey shaded coupling point of the
Fluidic Muscle press station. Hold down the left mouse button and
drag the coupling point to the free coupling point of the Pick &
Place station.

17. Add the sorting station as the last station. Connect the sorting
station to the Fluidic Muscle press station.
18. The system is now configured. Change into the view mode to obtain
a realistic 3D representation of the system.
Deactivate the Edit Mode command in the Modeling menu by
clicking onto the Edit Mode command. The check mark next to the
Edit Mode entry is removed.

19. A 3D representation of your system is displayed. The representation

also shows a top view.

20. To obtain a perspective view of the 3D model, select the Standard

Views/Default Settings command in the View menu. Move, rotate
and zoom into an appropriate view of your system by using the
commands under View.
21. Prior to simulating production of the system, the system should be

in the initial position. This is achieved by executing the Reset
Workcell command in the Simulation menu. By executing this
command, all the workpieces on the system are also removed.

22. Now activate the Start command in the Simulation menu.

Simulation of the system is now active. You can identify the
simulation mode via the Running entry.
23. Each station has an internal PLC. The supplied sample PLC program
is executed with the start of virtual system simulation.
The stations can now be operated using the keys and switches of
the corresponding control console. The sequence of operation is
defined in the PLC program.
24. Once simulation is started, the illuminated reset button requests the
reset function for all stations. The system is moved into the initial
position via the reset function.

25. To obtain information in the technical documentation regarding the

initial position of the system, open the CIROS Advanced
Mechatronics Assistant. Activate the Examples and Models of
CIROS Advanced Mechatronics command in the Help menu. Click
onto the CIROS Advanced Mechatronics entry. In the chapter
MPS Standard you will find the required information regarding the
individual stations in the technical documentation.

Result Initial position for the handling station: Linear axis in "predecessor
station" position (1B2=1) and lifting cylinder retracted (gripper up)
and gripper open.
Initial position for the Pick & Place station: Feed separator advanced
and conveyor motor off. Mini slide up and mini slide retracted and
vacuum off.
Initial position for the Fluidic Muscle Press station: Linear drive
retracted and rotary drive in pick-up position ("predecessor station
position") and pressb up.
Initial position for the sorting station: Locking device advanced and
sorting gate 1 retracted and sorting gate 2 retracted and conveyor
motor off.

26. Execute the reset function for each station by clicking the reset
button. We recommend that you carry out the reset of the individual
stations against the material flow.
In the case of this system, this means: Execute the reset mode of the
sorting station, then the reset mode of the Fluidic Muscle press
station, followed by that of the Pick & Place station and finally the
reset mode of the handling station.
27. The illuminated start button of a station indicates that the

respective station is now in the initial position.
28. Check whether the start conditions for the individual stations are
fulfilled. You will find the information for this in the technical
documentation for the individual station in CIROS Advanced
Mechatronics Assistant.

Result Start conditions of the individual stations:

Handling station: Workpiece in the workpiece holde
Pick & Place station: No workpiece at conveyor start and slide with
workpiece inserts filled
Fluidic Muscle press: No workpiece in gripper
Sorting station: No workpiece at conveyor start
29. Make sure that the workpieces necessary for the production process
of the system are available:
One workpiece housing at the transfer position of the handling
station,
At least one workpiece insert on the slide of the Pick & Place
station.

30. To supply a workpiece to the handling station, click onto the desired
workpiece on the workpiece table. For example select the red
measuring instrument housing. Then click onto the symbolic
workpiece of the handling station.
A red measuring instrument housing is made available on the
workpiece holder of the handling station.

31. Now fill the slide of the Pick & Place station with measuring
instruments by clicking onto the symbolic measuring instrument of
the Pick & Place station.

32. Start the sequence of each station by clicking onto the start button.
The automatic mode of the station is started. We recommend that
you start the stations in the order in which they are arranged in the
material flow.
33. With the key actuator you can select either continuous cycle (switch
position vertical) or individual cycle (switch position horizontal) for a
station sequence.
34. The sequence of a station can be interrupted at any time by pressing
the stop button. If you want to restart the station, you need to
execute the reset function first.

35. If a slide of the sorting station is filled with workpieces, the station
does not accept any additional workpieces. Warning light Q1 is
illuminated.

36. Remove the workpieces by executing the appropriate command in

the manual operation window.
Click onto the Manual Operation command in the Modeling menu.
Double click onto the + symbol in front of sorting station on the left
side of the window to display all the activities of the station.
Double click the Empty Slides entry.

37. Acknowledge the removal of the workpieces by pressing the start

button. The production process of the system is then continued.

7. This is how you analyse information flow in a
distributed system
The exercise is intended as an introduction to the subject of networking

stations. The networking is dealt with in the form of an example using
the distributing, testing and sorting stations.
The PLC programs are created such that they can be used for stand
alone operation of the stations. At the same time, these PLC programs
also support working with the stations in a network whereby minimal
information about process inputs/outputs is exchanged between the
stations.
In the standard version, MPS Standard stations are coupled with

optical sensors. This type of coupling is known as StationLink. Through-
beam sensor emitters and receivers are used as StationLink sensors.
The StationLink emitter is mounted on the material input side of the
station and the StationLink receiver on the material output side. By
switching on and off the StationLink emitter, the predecessor station
signals whether it is ready to accept a workpiece or occupied.
Note In the case of the distributing station only the StationLink receiver is
mounted.
In the case of the sorting station, only the StationLink emitter is
mounted.
The user analyses how simple communication functions and how it is

realised.

7. This is how you analyse information flow in a distributed system
7.1 The following training aims can be taught with the use of CIROS
Training aims Advanced Mechatronics:
Understanding simple communication between the stations of a
distributed system.
Realising simple communication between stations via process
inputs/outputs.
Incorporating simple communication into the PLC program of a
station.
Understanding structured, programmed PLC programs.
Evaluating technical documentation.
Researching information.
Recognising the advantage of a simulated system for industrial
operation.
7.2 Proceed step by step to analyse the networking and information flow in
Methods a system. Each step deals with an important aspect of communication.
The main aspects of communication are listed below.
Questions regarding the individual aspects offer suggestions and

guidance as to what you should examine and consider.

Main aspects Questions
Function of communication What is the function of communication?

To ensure the safe transfer of workpieces
To transmit information regarding the workpieces
To pass on job orders to the stations
Information that is exchanged How does communication function?

What is the meaning of the signal which the information transmits?
Via which absolute address is the signal evaluated?
What data type is the signal?
Realisation of communication How is communication realised?

Via the coupling of PLC inputs/outputs
Via the use of a fieldbus
Components for communication What components are used to establish communication:

Direct connection of PLC inputs/outputs
Optical sensors for signal transmission
Communication modules in field devices
Structure of communication How are the components assembled?

What needs to be considered when connecting stations?
Connection of components What does the connection of components look like?
Communication in PLC How is communication incorporated into PLC programs?

programs Is communication information transmitted to the relevant program
sections via global variables or via parameters?
Main aspects of communication within a system

7.3 CIROS Advanced Mechatronics supports you as follows during the

Support via CIROS analysis of communication in distributed systems:
Advanced Mechatronics Simulation of the modelled system in 3D representation and
execution of sample PLC programs in the internal controllers of
individual stations.
Windows for PLC inputs/outputs:
Status display of the inputs/outputs of a station.
Manual operation window:
Status display of all process activities and process statuses.
Manual operation window:
Status display of communications links.
CIROS Advanced Mechatronics Assistant:
Online information such as descriptions, circuit diagrams and PLC
programs of stations.
7.4
Example: Analysing
information flow in a
distributed MPS
Standard system
Exercise Analyse the communication in an MPS Standard system. Select the

combination of the distributing, testing and sorting stations as the
system. Consider the following questions when analysing the
communication:
What is the function of communication?
What information is exchanged?
How is communication realised?
Via what components is communication established?
How are the components assembled, what is to be considered when
coupling the stations?
What does the connection of components look like?
How is communication incorporated into the PLC programs?

Implementation 1. Start CIROS Advanced Mechatronics.

2. Create an MPS Standard system consisting of the distributing,
testing and sorting stations.
As the distributing station is coupled with the testing station, select
the station with the library entry Distributing Adjusted for Testing
in the model library.
3. Deactivate the Edit Mode as soon as the station is created. Change

to View mode by clicking the Edit Mode command in the Modeling
menu. The check mark next to the Edit Mode entry is removed.

4. Close the model library and select a perspective view of the system
by activating the Standard Views/Default Setting command in the
View menu. Using the command in the View menu, create the
desired representation of the system.

5. Refer to the technical documentation on the online Help to find out

what functions communication realises in MPS Standard systems.
To do so, activate the Examples and Models of CIROS Advanced
Mechatronics command in the Help menu. Click onto the CIROS
Advanced Mechatronics entry. In the chapter Getting Started you
will find a section about communication between stations.

Result The function of communication is to enable the reliable transfer of a

workpiece from the distributing station to the testing station.

6. Use the technical documentation for the two stations for information
as to how communication functions:
Which information is transmitted?
Which data type carries the signal which transmits information?
Result
Distributing station Testing station
Material flow
Station occupied bit
Station occupied = 1 means:

Testing station has no
requirement. Distributing station
must not output.
Station occupied = 0 means:
Testing station has requirement
and requests a workpiece.
Distributing station is permitted
to output.

7. Refer to the technical documentation for the two stations to find out
what system resources the PLC uses to realise communication.
To do so activate the Examples and Models of CIROS Advanced
Mechatronics command in the Help menu. Click onto the CIROS
Advanced Mechatronics entry. In the chapter MPS Standard you
will find the appropriate stations and relevant technical
documentation.

Result
0-Signal 1-Signal
1-Signal 0-Signal
The signal is inverted

at the receiving end.
Information is exchanged Information is exchanged

via via
Input of the PLC Input of the PLC
Output of the PLC Output of the PLC

I 0.7 Q 0.7

8. Refer to the technical documentation for the two stations to find out
which components are used to transmit the information "Station
occupied".
Result Components of the distributing station

Optical sensor: Through-beam sensor, receiver
Components of the testing station
Optical sensor: Through-beam sensor, emitter
9. Find out what is to be considered when coupling the stations.
Result To ensure that the communication signal is transmitted error-free via

the optical StationLink sensors, the optical sensors of the neighbouring
stations must be positioned flush and directly opposite one another.
This can be achieved by connecting the stations via the coupling points.
10. Refer to the technical documentation to find out where in the

diagram the components for the realisation of communication are
taken into account.
Result Sheet Column Designation
Circuit diagram of distributing station
4 9 Sensor IP_FI, through-beam sensor,

receiver
Circuit diagram of testing station
5 9 Sensor IP_N_FO, through-beam sensor,

emitter

11. Now observe the production process of the system.

Start simulation by activating Start in the Simulation menu.
12. The illuminated reset button requests the reset function on all
stations.
13. Reset the individual stations agains the material flow.

14. Make sure that the required workpieces are available for the
production process of the system.
Fill the magazine of the distributing station with, for example, red
basic cylinder bodies. To do so, click onto the required workpiece on
the workpiece table. Then click onto the symbolic workpiece on the
distributing station. Each mouse click on the symbolic workpiece
causes the magazine to be filled with a workpiece.

15. Start the sequence of each station by clicking onto the start button.
We recommend that you start the stations in the order in which they
are arranged in the material flow.
16. Once all the workpieces have been tested and sorted, stop the
simulation by clicking onto the Running field.

17. Next observe the status of the communication variables during the
production process of the system.
To do so, open the Manual Operation window in the Modeling
menu.
18. Hide the section of the window with the display of I/O connections
as you do not need this information. Activate the context-sensitive
menu via the right mouse button and deactivate the Show I/O
Connections command.
19. If you merely want to observe the changes in communication
signals, then set the stops at the appropriate signals. Simulation
stops as soon as the relevant signal changes its value and you can
observe the sequence at your leisure.

20. Double click the + symbol in front of the distributing station in the
lefthand section of the window. All the process sequences of the
distributing station are now displayed.
The process statuses of the testing station can be displayed in the
righthand section of the window.

21. Highlight the variable IP_N_FO station occupied of the testing

station under Process Status and set a stop. Open the context-
sensitive menu of the righthand mouse button and select the Stop
at Value Change command. The variable IP_N_FO is marked with a
STOP symbol.

22. Open the PLC inputs window to also observe the communication
signal of the distributing station.
Activate the Show Inputs command under Inputs/Outputs in the
View menu.

23. Select the controller whose PLC inputs/outputs you want to

observe. Click onto the Controller Selection command in the
Programming menu. In the Current column, select the controller for
the distributing station as controller.
24. Start simulation of the system by clicking onto the Stopped button
in the status bar.

25. The indicator light Q1 on the control console of the distributing

station indicates the workpieces are missing.
26. Fill the magazine of the distributing station with correct workpieces
again.
27. Acknowledge the activity and click onto the illuminated start button.

28. The distributing station ejects a new workpiece from the magazine
and passes it on to the testing station. Simulation then stops
because the Variable IP_N_FO of the testing station changes its
value. The testing station signals "station occupied=1", because
the station has no requirement. A workpiece is already present in
the holder.
29. Restart simulation to continue the execution of the production

process by clicking onto the Stopped button in the status bar.

30. In the next simulation cycle, the signal STATION_IP_FI successor

station free of the distributing station is updated in the Inputs
window. Its value is changed to 0. The distributing station must
therefore not pass on a further workpiece to the testing station.

31. The testing station now tests the current workpiece. As soon as the
station has completed the process of testing and passed on the
workpiece to the sorting station, it can accept a new workpiece. The
testing station changes the value of the variable IP_N_FO. It now
sends the signal "Station occupied=0". The signal change causes
simulation to stop.
32. Restart simulation.

33. In the next simulation cycle, the signal "station occupied" is read
inverted as "successor station free" by the distributing station. It is
therefore permissible for the distributing station to start output.
34. With the simulation of the system you have now analysed how
communication between the distributing and testing stations
functions.
In the GRAFCETs for the stations you can reproduce in detail how
and at which points in the PLC program communication is taken into
consideration. You will find the GRAFCETs in the technical
documentation for the stations.

35. You can analyse the communication between the testing and sorting
stations in the same way by using simulation and the technical
documentation.


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CIROS

Festo Didactic GmbH & Co. KG, 73770 Denkendorf, 2006-2010

The copying, distribution and utilisation of this document as well as the

1. What will you learn from the manual? ____________________ 5

2. This is how you install CIROS Advanced Mechatronics _____ 8

3. The CIROS Advanced Mechatronics system _____________ 11

4. Main control functions of CIROS Advanced Mechatronics __ 38

Festo Didactic GmbH & Co. KG 572761 3

4.12 Controlling a station of the system using

5. These training contents can be taught using

6. This is how you create and operate a distributed

7. This is how you analyse information flow in

4 Festo Didactic GmbH & Co. KG 572761

CIROS Advanced Mechatronics is a tool whereby you

The individual contents can be extended in complexity depending on

Festo Didactic GmbH & Co. KG 572761 5

Target group The manual is intended for

6 Festo Didactic GmbH & Co. KG 572761

CIROS Help contains detailed information regarding the functions and

The CIROS Advanced Mechatronics Assistant provides detailed

An Adobe Acrobat Reader must be installed on your PC to enable you to

Festo Didactic GmbH & Co. KG 572761 7

To install CIROS Advanced Mechatronics you will need the CIROS

For further information regarding system requirements, installation and

2.1 To be able to simulate a modelled system, a PLC program must be

If you are working with the default settings of CIROS Advanced

8 Festo Didactic GmbH & Co. KG 572761

By using this procedure, the default PLC programs used

CIROS Advanced Mechatronics supports you in the user-specific

CIROS Advanced Mechatronics differentiates between reference

Festo Didactic GmbH & Co. KG 572761 9

User models, if created and opened with the help of CIROS

10 Festo Didactic GmbH & Co. KG 572761

The following form part of CIROS Advanced Mechatronics:

3.1 CIROS Advanced Mechatronics is a PC-based graphic 3D simulation

A distributed system consists of one or several stations. One station is

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CIROS Assistant CIROS Help

System consisting of station models

Library Station 1 Station 2 Station 2 ...

Easy S7-PLCSIM CoDeSys PLCWinNT

Component parts of CIROS Advanced Mechatronics

The following is required in order to simulate the operation of a

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Each station is stored in a library together with a sample PLC program.

If a system is now modelled from the prepared stations, the

This facility enables you to simulate the operation of a system

One particular additional function provided by CIROS Advanced

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The monitoring and analysing of processes and the elimination of faults

The following are possible as external PLC:

CIROS Advanced Mechatronics requires the software program EzOPC

Note In addition to the ready-made process models, CIROS Advanced

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All stations are prepared for your use:

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Example of an MPS Standard system

Example of an MPS 500-FMS system

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The stations are available from two libraries:

Due to the technological functions of the individual stations and if using

MPS systems perform different production processes:

3.3 To ensure the correct sequence of the production process, the

In the case of MPS Standard systems a station usually communicates