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Flexibility and standardization using dynamic IO addressing and option handling


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This presentation will dive into solutions that DMC developed that fully leverage S7’s hardware and development flexibility to create efficient and agile manufacturing deployments.

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Flexibility and standardization using dynamic IO addressing and option handling

  1. 1. Flexibility and Standardization Using Dynamic IO Addressing and Option Handling David Berno, DMC Inc © Siemens 2019
  2. 2. Unrestricted © Siemens Industry, Inc. 2019 Page 2 2019 Automation Summit • Title:Flexibility and Standardization Using Dynamic IO Addressing and Option Handling • Track: PE • Presenter: David Berno • Company: DMC • Session # (for your survey): 11.2
  3. 3. DMC Overview Established in 1996, offices in Chicago, Boston, & Denver and customers throughout the world Established in 1996, DMC serves customers worldwide from offices in Chicago, Boston, Dallas, Denver, Houston, New York, Seattle, and St. Louis employees & growing 170+
  4. 4. DMC has the highest number of S7 certified engineers in the US. Siemens Expertise 35+
  5. 5. DMC Customers
  6. 6. Industries Served Energy & Utilities Printing Automotive Food & Beverage Semiconductor Chemical Oil & Gas Engineering Specialty Machinery Consumer Goods Packaging Machinery Programming Telecommunications Defense Contracting Pharmaceutical Test & Measurement
  7. 7. David Berno Systems Engineer • BS Mechanical Engineering • The University of Notre Dame • With DMC since 2016 • SIMATIC Technical Certification Presenter Info
  8. 8. 1. Option Control 2. Dynamic IO Addressing 3. Case Study 4. Comparison 5. Questions
  9. 9. Pain points for managing IO: • Managing slightly different hardware configurations • Managing a large volume of IO • What tools as a programmer do you have for dealing with complexity and scale? IO Management
  10. 10. • System constants that are created when a hardware configuration is built • Software key to unlocking a variety of different things regarding a piece of hardware Hardware Identifiers
  11. 11. • A machine is built with multiple different configurations • Each configurations adds or subtracts hardware from the system, either at the module or the slot level Option Control
  12. 12. • Allows hardware modules to be designated as optional in the hardware configuration Optional Hardware Modules
  13. 13. • A data record is created to reconfigure either the entire Profinet IO system or a single module on the network Data Records
  14. 14. • A data record is created to reconfigure either the entire Profinet IO system • PLC can be left in RUN mode Data Records – Module Level
  15. 15. • Uses the hardware identifier for the Profinet IO system to disable, reconfigure and the enable all optional hardware ReconfigIO function
  16. 16. • Data records can also be configured to changed the slot configuration on a remote IO rack Data Records – Slot Level
  17. 17. • Uses the hardware identifier for the module to reconfigure the slot WRREC function
  18. 18. • Tiered control system offerings at volume • Future potential expansion to existing control system • No programmer needed to change hardware configuration When should I use option control?
  19. 19. • Standard approach - create PLC tags that are linked to I & Q addresses that correspond to an IO rack or device • IO tags are manually named, linked and used throughout the code Large Volume of IO
  20. 20. Standard IO Addressing
  21. 21. • Tedious, time consuming process especially when dealing with a large number of IO points • Why not skip the middleman of PLC tags and have the function block look up the I&Q addresses it should be using? Standard IO Addressing
  22. 22. Dynamic IO Addressing Hardware identifiers and extended instructions: 1. RD_ADDR 2. PEEK 3. POKE
  23. 23. RD_ADDR • Queries a hardware identifier and returns the associated I & Q addresses • The process image associated with the hardware can now be read from and written to in the PLC program
  24. 24. PEEK • Used to read the value from the I addresses returned from the RD_ADDR function
  25. 25. POKE • Used to write a value to the Q addresses returned from the RD_ADDR function
  26. 26. Case Study – Automotive Assembly • DMC worked with a tier 1 automotive supplier whose assembly lines provided a unique framework for flexible IO addressing • Each assembly line is divided into zones and stations
  27. 27. Case Study – Automotive Assembly • Extraordinarily large hardware configuration
  28. 28. Hardware • 1 S7-1518F PLC per assembly line • ET200 Remote IO • 3rd Party Devices – cameras, scanners, torque tools etc.
  29. 29. Case Study – Automotive Assembly • Each station has the option to contain the following devices: • Pick to lights • Camera • Scanner • Torque Tool • Digital Inputs • Digital Outputs • And many more
  30. 30. Maximizing Indirect Addressing • Each device FB is assigned a zone, station and number • These three items create a unique identifier that each function block can use to look up a different hardware address • Each function block is able to be reused across all zones and stations and even assembly lines without changing the code • Standard wiring scheme is defined and followed for each device without exception
  31. 31. Case Study – Automotive Assembly • Customer Benefits • Reduced IO check time significantly • Reduced programming errors with mislinked IO • Provided easier field wiring for electricians • Creates an easily expandable framework for making hardware additions to the line • Allows reuse of device logic across assembly lines
  32. 32. dbHWIdentifiers • Arrays of zone, station and device types used for storing HW identifiers and device type
  33. 33. dbHWAddresses • HW Identifiers are parsed using the RD_ADDR function to determine the input and output addresses used
  34. 34. Device Example – Pick to Light • The pick to light is a common device used for reducing error in the selection of parts in the assembly process
  35. 35. Pick Light IO Map – Type 1
  36. 36. Pick Light IO Map – Type 2
  37. 37. fbPickLight • Contains logic for controlling a generic set of outputs with optional corresponding inputs – depending on the type • Peek function used to read input status of feedback from picklights • Poke function used to write outputs to the picklights for controlling the status and color
  38. 38. When should I use indirect addressing for my IO? • Large amount of IO • Standard wiring schemes • 3rd party devices with standard interfaces
  39. 39. Option Control vs Indirect Addressing Option Control Indirect Addressing Multiple deployments of different configurations Large Volume of IO Reduce programmer involvement Standardized IO mapping Manage a known number of hardware configurations Reduce overhead of PLC tag creation • Do not need to be used exclusively!
  40. 40. Takeaway • Before you begin your next project, think outside the box when it comes to how you interact with your IO • Consider option handling for any hardware that may be added or subtracted in the future • Consider indirectly addressing your IO where possible to reduce the number of PLC tags that must be created and linked
  41. 41. Questions?