Real-Time Factory

Overview

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 Overview
The Manufacturing Model

The Manufacturing Model for Real-Time Data Processing (Room E13)

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 Overview
Schematic Overview

Manufacturer: Festo Didactic Sorting Input

Transport
Transport Transport
Outgoing Ingoing
Outgoing
Modules:
2x Input
2x Output (Sorting) Storage

2x Transportation Processing
Processing

4x Work Stations
Storage Processing

Processing

Sorting Input

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 Overview
Overview about usage

Usage in courses
• Modules are distributed
between groups
• Each module has to be
programmed individually
and is controlled by its own
controller

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 Overview

Loads
RTAI Kernel PhoenixContact
modules Modbus TCP ModbusTCP coupler
for digital/analog I/Os

Industrial PC I/O signals

Development running
PCs RTAI Linux

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Overview

TCP/IP network

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Overview

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 Overview

RTAI
Scheduler

RT Process: RT Process: RT Process: RT Process:

Ejector 1 Ejector 2 Ejector 3 Stopper

Sync Sync

Sync

Sync Sync Sync

Inter-Process
Communication
handled by RTAI OS

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 Overview

RTAI
Scheduler

RT Process: RT Process: RT Process: RT Process:

Ejector 1 Ejector 2 Ejector 3 Stopper

Sync Sync

Sync

Sync Sync Sync

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Overview
Examples for Parallelity – Module internal

Ejectors Stopper

Slides

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Overview
Examples for Parallelity – Between modules

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Overview
Examples for Parallelity – Between modules

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 Real-time Factory
Module: Input

Magazines

In front of Behind Mag 2 1 2 3 Ejector

Mag 2

Pusher
Height Sensor

Slide

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 Real-time Factory
I/Os in Input Module

Inputs Bit Sensor

Outputs
0 Magazine 1 Pusher retracted Bit Digital Actuators
1 Magazine 1 Pusher extended 0 Retract Magazine 1 Pusher
2 Magazine 1 empty 1 Extend Magazine 1 Pusher
3 Magazine 2 Pusher retracted 2 Retract Magazine 2 Pusher
4 Magazine 2 Pusher extended
3 Extend Magazine 2 Pusher
5 Magazine 2 empty
4 Extend Ejector
6 Piece behind Magazine 2
5 Retract Magazine 3 Pusher
7 Magazine 3 Pusher extended
8 Magazine 3 Pusher extended
6 Extend Magazine 3 Pusher

9 Magazine 3 empty 7 Conveyor on

10 Ejector retracted
11 Ejector extended
12 Height sensor registered piece
Address Analog Actuator

13 Height sensor measured: Piece is ok 0 Height value

14 Slide full
15 Piece in front of Magazine 2

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Real-time Factory
Module: Distribution Center Input (Input 2)

Magazines
Height Ejector Output
Sensor Conveyor
Main Conveyor

Seperator
Seperator (main)
(side) Slide
Side Conveyor
Magazine 4

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 Real-time Factory
I/Os Distribution Center Input (Input 2)

Inputs Bit Address Digital Sensor Bit Address Digital Sensor Address Analog Sensor
0 8002 Conveyor (Side) Piece at end 16 8001 Magazine 3 is retracted 0 Height value
1 8002 Conveyor (Output) Piece at end 17 8001 Magazine 3 is ejected
2 8002 Conveyor (Main) Piece at begin 18 8001 Piece in Magazine 3
3 8002 Conveyor (Main) Piece between Mag 1+2 19 8001 Ejector in right position
4 8002 Conveyor (Main) Piece between Mag 2+3 20 8001 Ejector in left position
5 8002 Conveyor (Main) Piece in front of Ejector 21 8001 Ejector in middle position
6 8002 Seperator (Main) is set 22 8001 Ejector lock is set
7 8002 Seperator (Main) Piece in front 23 8001 Slide full
8 8002 Seperator (Side) is set 24 8001 Height sensor: Piece not ok
9 8002 Seperator (Side) Piece in front 25 8001 Height sensor: Measurement
correct
10 8002 Magazine 1 is retracted
11 8002 Magazine 1 is ejected
12 8002 Piece in Magazine 1
13 8002 Magazine 2 is retracted
14 8002 Magazine 2 is ejected
15 8002 Piece in Magazine 2

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 Real-time Factory
I/Os Distribution Center Input (Input 2)

Outputs Bit Address Digital Actuator Bit Address Digital Actuator Address Analog Actuator
0 8012 Stop Conveyor (Main) 16 8011 Move Ejector left 0 Conveyor (Output) Speed
1 8012 Slow down Conveyor (Main) 17 8011 Activte lock in Ejector (Middle pos)

2 8012 Move Conveyor (Main) left

3 8012 Move Conveor (Main) right
4 8012 Turn Conveyor (Side) on
5 8012 Conveyor (Output) backward
6 8012 Conveyor (Output) forward
7 8012 Set Seperator (Main)
8 8012 Set Seperator (Side)
9 8012 Eject Magazine 1
10 8012 Eject Magazine 2
11 8012 Eject Magazine 3
12 8012 Retract Magazine 1
13 8012 Retract Magazine 2
14 8012 Retract Magazine 3
15 8012 Move Ejector right

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Real-time Factory
Module: Processing

Checker Drill

2 3
Ejector A

Ejector B

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 Real-time Factory
I/Os in Processing Module

Inputs Outputs

Bit Sensor Bit Actuator

0 Piece in Postion 1 0 Turn drill on

1 Piece in Position 3 (Drill) 1 Turn turntable*

2 Piece in Position 2 (Checker) 2 Move drill up

3 Drill up 3 Move drill down

4 Drill down 4 Lock piece in drill position

5 Turntable in position 5 Extend checker

6 Checker fully extended (Piece OK) 6 Extend Ejector B

7 Extend Ejector A

*turntable only needs impulse to rotate exactly

one position

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Real-time Factory
Module: Sorting

Ejectors Stopper

Slides

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 Real-time Factory
I/Os in Sorting Module

Inputs Bit Sensor Outputs Bit Actuator

0 Piece arrived 0 Switch Conveyor on
1 Piece is metal 1 Extend Ejector 1
2 Piece is not black 2 Extend Ejector 2
3 Slide 1 full 3 Extend Ejector 3
4 Slide 2 full 4 Open Stopper
5 Slide 3 full
6 Piece reached end of conveyor
7 Ejector 1 retracted
8 Ejector 1 extended
9 Ejector 2 retracted
10 Ejector 2 extended
11 Ejector 3 retracted
12 Ejector 3 extended
13 Piece passed Ejector 1
14 Piece passed Ejector 2

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Real-time Factory
Module: Storage

Directly addressable positions

B
A C

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 Real-time Factory
I/Os in Storage Module

Inputs Outputs

Bit Sensor Bit Actuator

0 Movement in x position allowed 0-3 X coordinate**
1 Movement in x position done 4 Start movement in x direction
2 Movement in y position allowed 5-8 Y coordinate**
3 Movement in y position done 9 Start movement in y direction
4 Gripper up 10 Move gripper up
5 Gripper down 11 Move gripper down
6 Gripper open 12 Open gripper
7 Gripper closed 13 close gripper
8 Piece under gripper* 14 Allow movement
9 Safety door closed 15 Turn light on
*always senses piece one position right of the **the coordinates are mapped in 4 bits each,
gripper position allowing values between 0 and 15

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 Real-time Factory
Storage

Bit Actuator
Dec Function 0-3 X coordinate**
0 Reference Position of the linear axis 4 Start movement in x direction
1-9 x/y coordinate 5-8 Y coordinate**
10 Conveyor A 9 Start movement in y direction
11 Conveyor B 10 Move gripper up
12 Conveyor C 11 Move gripper down
13 - 12 Open gripper
14 Single Step in positive direction 13 close gripper
Directly addressable positions
15 Single Step in negative direction 14 Allow movement
B 15 Turn light on
A C

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Real-time Factory
Modules: Transportation

Transport Outgoing Transport Ingoing

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Real-time Factory
Switches in the Transportation Modules

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Real-time Factory
Conveyor belts in the Transportation Modules

Sensors

Direction

Front End

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 Real-time Factory
Transport Input

Transport Input Conveyor Register Forward Backward

Conveyor Register Piece at
front
Piece
at end

- Conveyors A 8019 0 1 A 8002 0 1

B 8019 2 3 B 8002 2 3
C 8019 4 5 C 8002 4 5
D 8019 6 7 D 8002 6 7
H 8018 4 5 H 8001 4 5

Actuators

Sensors
I 8018 6 7 I 8001 6 7
J 8018 8 9 J 8001 8 9
L 8018 14 15 L 8001 14 15
M 8021 0 1 M 8004 0 1
P 8021 10 11 P 8004 10 11
Q 8021 12 13 Q 8004 12 13
R 8021 14 15 R 8004 14 15
U 8020 8 9 U 8003 8 9
V 8020 10 11 V 8003 10 11

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 Real-time Factory
Transport Input

Transport Input - Switches

Switch Register Pos In Piece in

Switch Register Ref. Pos 1 Pos 2 Pos 3 reached movement switch
E 8019 8 9 10 11 E 8002 8 9 10
F 8019 12 13 14 15 F 8002 12 13 14
G 8018 0 1 2 3 G 8001 0 1 2
K 8018 10 11 12 13 K 8001 10 11 12
N 8021 2 3 4 5 N 8004 2 3 4
O 8021 6 7 8 9 O 8004 6 7 8
S 8020 0 1 2 3 S 8003 0 1 2
T 8020 4 5 6 7 T 8003 4 5 6
W 8020 12 13 14 15 W 8003 12 13 14

Actuators Sensors

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 Real-time Factory
Separators in the outgoing Transportation module (inside storage)

Actuators
Separator Set Behind
1 64
Separator 1
2 67
3 70
Separator

Sensors Separator 2
In front
Separator Piece Piece in
behind front
1 65 66 Separator 3
2 68 69
3 71 72

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 Real-time Factory
Transport Output

Conveyor Register Piece Piece at

Transport Output
Conveyor Register Forward Backward at front end
A 8019 0 1 A 8002 0 1

- Conveyors B 8019 2 3 B 8002 2 3

D 8019 8 9 D 8002 8 9
E 8019 10 11 E 8002 10 11
G 8018 0 1 G 8001 0 1
H 8018 2 3 H 8001 2 3

Actuators

Sensors
I 8018 4 5 I 8001 4 5
K 8018 10 11 K 8001 10 11
L 8018 12 13 L 8001 12 13
N 8021 2 3 N 8004 2 3
O 8021 4 5 O 8004 4 5
P 8021 6 7 P 8004 6 7
T 8020 4 5 T 8003 4 5
U 8020 6 7 U 8003 6 7
V 8020 8 9 V 8003 8 9
W 8020 10 11 W 8003 10 11
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 Real-time Factory
Transport Output

Transport Output - Switches

Switch Register Pos In Piece in

Switch Register Ref. Pos 1 Pos 2 Pos 3 reached movement switch
C 8019 4 5 6 7 C 8002 4 5 6
F 8019 12 13 14 15 F 8002 12 13 14
J 8018 6 7 8 9 J 8001 6 7 8
M 8018/8021 14 15 0 1 M 8001/8004 14 15 1
Q 8021 8 9 10 11 Q 8004 8 9 10
R 8021 12 13 14 15 R 8004 12 13 14
S 8020 0 1 2 3 S 8003 0 1 2
X 8020 12 13 14 15 X 8003 12 13 14

Actuators Sensors

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 ModbusTCP interface
Modbus Address Overview

Starting Address Starting Address

IP of Input of Output Port: 502
Registers Registers Unit Id: 1
Distribution Center Input (DZE) [Link] 8001 8011

Distribution Center Output (DZA) [Link] 8001 8009 Read: FC 03 (Read

Input (WE) [Link] 0 8003
Holding Registers)

Workstation 1 (B1) [Link] 8001 8003 Write: FC 16 (Write

Workstation 2 (B2) [Link] 8001 8003 Multiple Holding
Registers)
Workstation 3 (B3) [Link] 8001 8003

Workstation 4 (B4) [Link] 8001 8003

Transport In (TWE) [Link] 8001 8018

Transport Out (TWA) [Link] 8001 8018

Storage (LAG) [Link] 0 384

Output/Sorting (WA) [Link] 0 384

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 ModbusTCP interface
Setup

Modbus TCP

Modbus TCP
Bus coupler

ModbusTCP
ModbusTCP
Client

Module „Input“

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 ModbusTCP interface
ModbusTCP

ModbusTCP

• Standard for Data Exchange

• Modbus: Developed for communication between PLCs and
automation devices (Modicon, Schneider) -> field bus
• ModbusTCP: Ethernet-based variation

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 ModbusTCP interface
ModbusTCP

ModbusTCP – Basics

• Server: Provides data (passive)

• Client: requests data (active)
• Request: message sent from client to server to request data
• Response: server response message following a request
• Coil: Single In-/Output (1 Bit)
• Register: register with multiple in- and outputs (16 Bit) Modbus
Request Server
Modbus
Client
Response

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 ModbusTCP interface
Coils

ModbusTCP – Coils

Coil Address

0 0

1 1

2 1

...
...
9999 0

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 ModbusTCP interface
Registers

ModbusTCP – Register
Register SIze: 16 Bit (2 Byte or 1 Word)

Register Address

8001 0 1 1 0 0 1 1 0 1 1 1 0 0 0 1 0

8002 0 0 0 0 0 0 0 0 0 1 1 1 1 0 1 1

8003 0 0 0 0 0 0 0 0 0 1 1 1 1 0 1 1

...
...

39999 0 0 0 0 0 0 0 0 0 1 1 1 1 0 1 1

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 ModbusTCP interface
Readable Objects

ModbusTCP – Readable Objects

Object Access Size

Coil R/W 1 Bit
Discrete Input R 1 Bit
Holding Registers R/W 16 Bits
Input Registers R 16 Bits

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 ModbusTCP interface
Function Codes

ModbusTCP – Function Codes

• Function Codes (FC) are transmitted with every request to the server, providing
him information about what to do (e.g. read, write, access to coils, access to
registers, etc.)
• Most important FCs for us:

FC Name Description FC Name Description

01 Read Coils Read n Coils starting at address x 05 Write Single Coil Write 0 or 1 into Coil x
02 Read Discrete Read n discrete Inputs starting at 06 Write Single Write Word (16 Bit) into Holding
Inputs address x Holding Register Register x
03 Read Multiple Read n Holding Registers starting 15 Write Multiple Write n Bits in Coils starting at
Holding Registers at address x Coils address x
04 Read Input Read n Input registers starting at 16 Write Multiple Write n Words (16 Bit each) in
Registers address x Holding Register Holding Register starting at
address x
Read Write

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 ModbusTCP interface
Connect

ModbusTCP – Step 1: Connecting

Connect Modbus Server

8001 0 1 1 1 0 1 0 1 1 1 0 1 0 1 0 1
Modbus IP address: [Link] 8002 0 0 0 0 0 1 0 0 1 1 0 1 0 1 1 1
Port: 502
Client Unit Number: 1
8003 1 1 1 1 0 1 0 1 0 0 1 1 0 0 0 0
8004 0 1 1 1 0 1 0 1 1 1 0 1 0 1 0 1

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 ModbusTCP interface
Read Request

ModbusTCP – Step 2: Request (Read)

Modbus Server
Request
8001 0 1 1 1 0 1 0 1 1 1 0 1 0 1 0 1
Modbus 8002 0 0 0 0 0 1 0 0 1 1 0 1 0 1 1 1
FC: 03 - Read Multiple Holding Registers
Client Starting Address: 8001 8003 1 1 1 1 0 1 0 1 0 0 1 1 0 0 0 0
Number of Registers: 2 8004 0 1 1 1 0 1 0 1 1 1 0 1 0 1 0 1

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 ModbusTCP interface
Read Response

ModbusTCP – Step 3: Response (Read)

Modbus Server
8001 0 1 1 1 0 1 0 1 1 1 0 1 0 1 0 1
Modbus 8002 0 0 0 0 0 1 0 0 1 1 0 1 0 1 1 1
Client Response 8003 1 1 1 1 0 1 0 1 0 0 1 1 0 0 0 0
8004 0 1 1 1 0 1 0 1 1 1 0 1 0 1 0 1

Register content =
[0]: 0111010111010101
[1]: 0000010011010111

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 ModbusTCP interface
Read Response

Modbus Server Phoenix Contact

ModbusTCP
8001 0 1 1 1 0 1 0 1 1 1 0 1 0 1 0 1 Bus coupler
Modbus 8002 0 0 0 0 0 1 0 0 1 1 0 1 0 1 1 1
Client Response 8003 1 1 1 1 0 1 0 1 0 0 1 1 0 0 0 0
8004 0 1 1 1 0 1 0 1 1 1 0 1 0 1 0 1

Register values =
[0]: 0111010111010101
[1]: 0000010011010111

Module/Asset „Workstation 1“

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 ModbusTCP interface
Write Request

ModbusTCP – Step 2: Request (Write)

Modbus Server
Request
8001 0 1 1 1 0 1 0 1 1 1 0 1 0 1 0 1
Modbus 8002 0 0 0 0 0 1 0 0 1 1 0 1 0 1 1 1
FC: 16 - Write Multiple Holding Registers
Client Starting Address: 8003 8003 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Number of Registers: 2 8004 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Register Values =
[0]: 0000000000000001
[1]: 0111010111010101

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 ModbusTCP interface
Write Response

ModbusTCP – Step 3: Response (Write)

Modbus Server
8001 0 1 1 1 0 1 0 1 1 1 0 1 0 1 0 1
Modbus 8002 0 0 0 0 0 1 0 0 1 1 0 1 0 1 1 1
Client Response 8003 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1
8004 0 1 1 1 0 1 0 1 1 1 0 1 0 1 0 1
FC: 16 - Write Multiple Holding Registers
Starting Address: 8003
Number of Registers: 2

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 pyModbusTCP
Overview

pyModbusTCP

• Python library for ModbusTCP communication

• [Link]
[Link]

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 pyModbusTCP
Connec

Connecting using pyModbusTCP

Client Lib

Client object IP address Port Unit ID

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 pyModbusTCP
Read Request

Read request using FC03 with pyModbusTCP

Starting Number of
register registers

Return value is a list! Each element of the list contains a

register value

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 pyModbusTCP
Test Bit

Helper function „test_bit“

Facilitates testing if a specific bit in a

register is set

Bit to be
Variable to be checked Checked (0-15)

Return Value:
True: Set (1)
False: Not Set (0)

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pyModbusTCP
Example Read

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 pyModbusTCP
Write Request

Write Request with FC16 and pyModbusTCP

List of register values

Starting to be written
register

Writing with FC16 expects a list as parameter!

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 pyModbusTCP
Set Bit

Helper function „set_bit“

Facilitates setting a specific bit at

position x in a register

reset_bit( ) does the opposite

Variable where Bit to be
Bit should be set set (0-15?)

Return Value:
Register with bit
Set at desired position

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pyModbusTCP
Example Write

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