¶ Overview
This guide is a walk-through of modeling techniques based on a discussion in 'Industry 4.0 Community' Discord.
¶ Machine Operation
The 'Strut Assembly Station' accepts strut housing and rod assemblies of varying sizes and applies proper torque to rod end fittings mated by the operator.
The operator inputs job information and production quantity into the human machine interface, presents a strut assembly, inserts end fittings, and cycles the machine. At cycle end, a label is printed and applied with relevant job information, and the assembly is removed.
¶ Model Planning
¶ Available Data
Below lists the available data points from the Rockwell logic controller.
After some discussion we arrived the the following draft of the controller states.
¶ Model Design
Using the XState library we created the controller state machine for later simulation and the MTConnect model itself.
¶ Simulated Controller Inputs
- SIG_POWER - Station power supply switch.
- SIG_JOB - Operator job information input.
- SIG_PRESENT_PART - Operator action of presenting part to fixture, engaging part detection proximity sensors.
- SIG_REMOVE_PART - Operator action of removing part from fixture, disengaging part detection proximity sensors.
- SIG_OPERATOR_START - Operator action pressing cycle start button.
- SIG_INTERRUPT - Operator action pressing E-Stop, breaking light curtain, or internal machine fault during cycle.
- SIG_RESET_FAULT - Operator action resetting fault via E-Stop or reset button.
¶ Simulated Controller Outputs
- Devices/PowerSwitch (0,1)
- Devices/ResetPushButton (0,1)
- Devices/HousingPartPresent (0,1)
- Devices/RodPartPresent (0,1)
- Devices/ValveManifold (0,1)
- Devices/EStop (0,1)
- Data/Job
- Data/CycleTime
- State/off
- State/on+setup
- State/on+idle
- State/on+ready
- State/on+running
- State/on+cycle_ended
- State/on+faulted
¶ Iteration #1
Model (click to expand)
<?xml version="1.0" encoding="UTF-8"?>
<MTConnectDevices
xmlns:m="urn:mtconnect.org:MTConnectDevices:1.7"
xmlns:xsi="http://www.w3.org/2001/XMLSchema-instance"
xmlns="urn:mtconnect.org:MTConnectDevices:1.7"
xsi:schemaLocation="urn:mtconnect.org:MTConnectDevices:1.7 https://schemas.mtconnect.org/schemas/MTConnectDevices_1.7.xsd">
<Header
creationTime="2021-09-20T00:00:00+00:00"
deviceModelChangeTime="2021-09-20T00:00:00+00:00"
sender="localhost" instanceId="12345678" bufferSize="131072" assetBufferSize="1000" assetCount="0" version="1.7.0.3" />
<Devices>
<Device id="strut-assy" name="Strut Assembly" uuid="sa1" sampleInterval="1000">
<DataItems>
<!--
https://model.mtconnect.org/#Architecture__efa904df-e614-4dde-81d4-3d9d41ea5596
origin: Devices\PowerSwitch, Devices\PowerSupply
-->
<DataItem category="EVENT" id="avail" name="availability" type="AVAILABILITY" />
<!--
https://model.mtconnect.org/#Architecture__f43a20be-9afb-4479-8d7a-a0d87a490143
values:
UNAVAILABLE: initial
SETUP: setup state
PRODUCTION: not setup state
TEARDOWN: idle state && job_completed=true
-->
<DataItem category="EVENT" id="func" name="functional_mode" type="FUNCTIONAL_MODE" />
</DataItems>
<Components>
<Controller id="controller" name="controller">
<Compositions>
<!-- safety -->
<Composition id="comp-estop" type="SWITCH"/>
<Composition id="comp-light-curtain" type="SENSING_ELEMENT"/>
<Composition id="comp-safety-relay" type="SWITCH"/>
<!-- work holding -->
<Composition id="comp-housing-clamp" type="CLAMP"/>
<Composition id="comp-valve-manifold" type="VALVE"/>
<Composition id="comp-housing-part-present" type="SENSING_ELEMENT"/>
<Composition id="comp-rod-part-present" type="SENSING_ELEMENT"/>
<!-- other -->
<Composition id="comp-reset-pushbutton" type="SWITCH"/>
<Composition id="comp-power-switch" type="SWITCH"/>
<Composition id="comp-power-supply" type="POWER_SUPPLY"/>
</Compositions>
<DataItems>
<!--
origin: Devices/EStop
-->
<DataItem category="EVENT" id="estop" type="COMPOSITION_STATE" subType="SWITCHED" compositionId="comp-estop"/>
<!--
origin: Devices/LightCurtain
-->
<DataItem category="EVENT" id="light-curtain" type="COMPOSITION_STATE" subType="ACTION" compositionId="comp-light-curtain"/>
<!--
origin: Devices/SafetyRelay
-->
<DataItem category="EVENT" id="safety-relay" type="COMPOSITION_STATE" subType="SWITCHED" compositionId="comp-safety-relay"/>
<!--
origin: Devices/HousingClamp
-->
<DataItem category="EVENT" id="housing-clamp" type="COMPOSITION_STATE" subType="MOTION" compositionId="comp-housing-clamp"/>
<!--
origin: Devices/ValveManifold
-->
<DataItem category="EVENT" id="valve-manifold" type="COMPOSITION_STATE" subType="ACTION" compositionId="comp-valve-manifold"/>
<!--
origin: Devices/HousingPartPresent
-->
<DataItem category="EVENT" id="housing-part-present" type="COMPOSITION_STATE" subType="ACTION" compositionId="comp-housing-part-present"/>
<!--
origin: Devices/RodPartPresent
-->
<DataItem category="EVENT" id="rod-part-present" type="COMPOSITION_STATE" subType="ACTION" compositionId="comp-rod-part-present"/>
<!--
origin: Devices/ResetPushbutton
-->
<DataItem category="EVENT" id="reset-pushbutton" type="COMPOSITION_STATE" subType="SWITCHED" compositionId="comp-reset-pushbutton"/>
<!--
origin: Devices/PowerSwitch
-->
<DataItem category="EVENT" id="power-switch" type="COMPOSITION_STATE" subType="SWITCHED" compositionId="comp-power-switch"/>
<!--
origin: Devices/EthernetSwitch
origin: Devices/HousingNutRunner
origin: Devices/IOBlock
origin: Devices/LabelPrinter
origin: Devices/LabelPresent
origin: Devices/LabelScanner
origin: Devices/PLC
-->
<!--<DataItem category="EVENT" id="power-supply" type="COMPOSITION_STATE" subType="SWITCHED" compositionId="comp-power-supply"/>-->
<!--
https://model.mtconnect.org/#Architecture__4e32a979-4ce0-40d2-b725-4488705ce7c5
-->
<DataItem category="SAMPLE" id="uptime" type="EQUIPMENT_TIMER" subType="POWERED" />
<!--
https://model.mtconnect.org/#Architecture__550918a4-def4-4def-a2db-30d85c4e066e
-->
<DataItem category="EVENT" id="execution" type="EXECUTION" />
<!--
https://model.mtconnect.org/#Architecture__b5a9fb61-fd07-4e9d-a7a5-83ead254c35d
-->
<DataItem category="CONDITION" id="system-condition" name="condition" type="SYSTEM" />
<!--
https://model.mtconnect.org/#Architecture__a2153eb8-f351-45a5-8b3d-5f7bc48aba8f
origin: Status/CycleCount
-->
<DataItem category="SAMPLE" id="cycle-count" type="CYCLE_COUNT" subType="ALL" />
<!--
https://model.mtconnect.org/#Architecture__6557d357-6c9a-43e2-ac74-5b1037f62770
origin: Devices/HousingPartPresent, Devices/RodPartPresent
-->
<DataItem category="EVENT" id="part-present" type="PART_DETECT" />
</DataItems>
<Components>
<ProcessOccurrence id="process_occurrence">
<DataItems>
<!--
https://model.mtconnect.org/#Architecture__ab12b881-f1da-4f5a-b91e-2d25b8a5a03e
origin: Production/WorkOrderNumber
-->
<DataItem category="EVENT" id="job-number" type="PROCESS_AGGREGATE_ID" subType="ORDER_NUMBER" />
<!--
origin: Production/PartNumber
origin: Production/CustomerNumber
-->
<!--
https://model.mtconnect.org/#Architecture__686755ea-ff11-4439-91a6-0a3b81216302
origin: work order info arrival
-->
<DataItem category="EVENT" id="job-start" type="PROCESS_TIME" subType="START" />
<!--
https://model.mtconnect.org/#Architecture__ef33cc84-1908-412a-bcf1-72ad572bf837
origin: part-count.remaining == part-count.target
-->
<DataItem category="EVENT" id="job-end" type="PROCESS_TIME" subType="COMPLETE" />
<!--
https://model.mtconnect.org/#Architecture__be00b027-3408-4419-bcbe-e6fbf0814d20
-->
<DataItem category="EVENT" id="proc-state" type="PROCESS_STATE" />
<!--
https://model.mtconnect.org/#Architecture__683746cd-c233-4e1d-8f37-d11f8d0856fd
origin: Status/CycleTime
-->
<DataItem category="SAMPLE" id="cycle-time" type="PROCESS_TIMER" subType="PROCESS" units="SECOND" />
<!--
https://model.mtconnect.org/#Architecture__a2c0c83f-b61b-4944-8bfa-d1d5385d62d3
origin: Status/Operator
-->
<DataItem category="EVENT" id="operator" type="USER" subType="OPERATOR"/>
<!--
origin: Production/Quantity
-->
<DataItem category="EVENT" id="pc-target" type="PART_COUNT" subType="TARGET" />
<DataItem category="EVENT" id="pc-complete" type="PART_COUNT" subType="COMPLETE" />
<DataItem category="EVENT" id="pc-remain" type="PART_COUNT" subType="REMAINING" />
<DataItem category="EVENT" id="pc-failed" type="PART_COUNT" subType="FAILED"/>
<DataItem category="EVENT" id="pc-good" type="PART_COUNT" subType="GOOD"/>
</DataItems>
</ProcessOccurrence>
</Components>
</Controller>
</Components>
</Device>
</Devices>
</MTConnectDevices>
¶ Iteration #2
TODO: revise model
¶ Simulation
Controller and MTConnect output simulated using NodeRed.
Live User Interface
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