Osai - PLC

Osai - PLC
 Osai - PLC

VERSION DATE DESCRIPTION OF REVISION DRAWN UP BY CHECKED BY

00.00 12/09/13 FIRST DOCUMENT DRAFT MAGRI MARCELLO

01.00 30/10/13 PROCEDURE REVISION BCK/RST FAUSTO ZANARDI LORIS VALSECCHI

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TABLE OF CONTENTS
Introduction ........................................................................................................................... 4
Purpose of document .............................................................................................................. 4

Description of Automation Project Parts .................................................................................... 4

CNC functions and PLC functions ............................................................................................. 5
NC – PLC interaction ............................................................................................................... 5

SW structure of the NC ........................................................................................................... 6

AMP ...................................................................................................................................... 7
Applications by Machining Centre Manufacturer ......................................................................... 7
WIN folder ............................................................................................................................. 8

PLC Structure ......................................................................................................................... 9

Variable Nomenclature .......................................................................................................... 10
TABLES OF SYMBOLS FOR I/O SIGNAL NOMENCLATURE ......................................................... 10
TABLE OF SYMBOLS FOR GLOBAL VARIABLE NOMENCLATURE................................................. 11
TABLE OF SYMBOLS FOR GLOBAL VARIABLE NOMENCLATURE (Volatile only) ........................... 12
NOTES AND EXAMPLES ......................................................................................................... 13
TABELLA DEI SIMBOLI PER NOMENCLATURA ULTERIORI STRUTTURE DATI ............................. 14

Debug PLC ........................................................................................................................... 15

Ricerche Veloci ..................................................................................................................... 17
ulteriori operazioni di debug .................................................................................................. 17

Backup & Restore CN ............................................................................................................ 18

Backup CN ........................................................................................................................... 18
Restore CN .......................................................................................................................... 23

Riferimenti ........................................................................................................................... 27

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INTRODUCTION

PURPOSE OF DOCUMENT
This document is meant for assistance support; therefore its aim is simplifying and speeding up
the diagnosis of any machining centre troubles.
For this purpose the following topics will be dealt with:
- Description of the main parts of OSAI automation project
- Description of the CNC and PLC basic structures and related interactions
- Description of PLC Debug operations
- Description of NC OSAI Backup and Restore operations

DESCRIPTION OF AUTOMATION PROJECT PARTS

The figure below displays the components of a typical NC OSAI Automation project

CNC AXES DRIVES

Peripherals canbus mechatrolink

PC
serial OFFICE

ethernet

INVERTER

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CNC FUNCTIONS AND PLC FUNCTIONS

The main component of the automation project is the CNC (Computer Numerical Control (referred
to as NC from now onwards)) which carries out the following functions:
a) Part-Program interpretation and execution
b) Interpolation and axis handling control
c) Management of Process Variables (E, @, L()…)
d) System parameterization

In particular, the NC OSAI integrates also the PLC (Programmable Logic Controller) of the
machining centre. The PLC consists of a program written in a programming language called
WinPLUS which, once compiled and transferred into the NC memory, is run by the CPU of the NC
cyclically.
The PLC carries out the following tasks:
a) Manages the “Machine interface logic” , that is, manages all the Inputs/Outputs
(digital/analog, local/remote) of the machine.
b) Informs the machining centre operator about any anomalies, detected via screen
messages or warning lights; attends to stop the machining centre functions temporarily or
definitively based on the seriousness of such anomalies.
c) Enables the workpiece machining process to progress (Part-Program) and checks that at
the beginning and end of each programmed block all necessary conditions exist to be able
to carry on machining.
d) Manages the requests made by the Part-Program via the M,S,T auxiliary functions.
e) Manages the requests made by the machining centre operator:
o selects the operation mode of NC (AUTOMATIC, MDI, JOG, HOMING …)
o starts, stops and resets the machining process
o manages the requests made via Softkey available on the PC OFFICE.
f) Manages the various automatic cycles so that they run concurrently with the machining
process.
g) Acquires process variable values and axis dimensions, checks axis-axis or axis-machine
frame collisions.

NC – PLC INTERACTION

DIRECT INTERACTON
The NC retentive memory houses a memory area called VARIABILI PLUS which you can access
both from PLC and NC (from Part-Program or by accessing the related variable list). This memory
are is provided with 256 full format variables (subdivided into boolean variables) and 64 floating
point variables.

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On the PLC side these memories subdivide into GW memories (bit-to-bit definable, in case) and in
GD memories respectively. On the NC side such variables are seen as variables @ follone by a max
10-character name. Type, name and address are declared in the special section “LOGIC CONF” in
AMP.
For any necessary in-depth details refer to the OSAI “AMP” Manual (code Osai 45006666T).

INDIRECT INTERACTION
The NC has a system memory area called area S; it also reserves part of the M area to interface
with the PLC transparently for the end user.
For instance, to carry out the following operations you need to:
- request for the PLC consent to execute each M,S,T code….
- request for the PLC consent to start moving an axis
- request for the PLC consent to declare an axis movement completed
While waiting for the PLC response, the NC stops the Part-Program execution on the wait
command.
The PLC cyclically controls the area S or area M memories, that are connected with the various NC
controls. After checking the presence of all necessary conditions, it attends to the specific
management and signals the acceptance of the request (ACK) on other memories to enable
continuing the processes under way.
For any necessary in-depth details refer to the OSAI “ WinPLUS Application” Manual (code Osai
45006861T).

SW STRUCTURE OF THE NC

This paragraph deals with the organization of the NC files and the description of the most
important ones, with regard to the purpose of this document.
The NC Hard Disk is partitioned into the following 4 logic partitions:
C and D : they are system disks containing the system files relating to the specific NC SW release.
E: this disk is reserved to the machining centre manufacturer, containing all NC parameterization
data.
F: this disk is reserved to the machining centre manufacturer and to the end used; it contains all
workpiece machining cycles (Part-Program) and any other machining centre operating cycles
(paramacro, tool change programs, etc.)
The peculiar files and folder are mentioned below:
E:\AMP : folder where the various AMP (Adjustable Machine Parameters) reside, i.e., the
system characterization files.

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E:\OEM\EXE : folder where the machining centre manufacturer applications reside (CMSKMG,
CMSCON, CMSRST). These DOS Real Time applications are run by the NC in parallel
with all other activities.
E:\LOG\WIN: folder containing some PLC configuration files, the message files
and the Canbus line configuration files.
F:\CMSKMG : folder containing the CMSKMG application configuration files.
F:\UPP : folder containing the Part-Programs and any auxiliary programs by the machining
centre manufacturer (tool change cycles, workpiece loading/unloading cycles, …)

AMP
By the related utility function it is possible to define up to 4 AMP’s. In most cases one single AMP is
enough for NC characterization. At other times it is necessary to define more than one of them, as
the machining centre can adopt configurations needing different parameterizations (machining
centres equipped with Gantry tables, machining centres where no axes can be added or removed
according to the operations to carry out, …). In this case it will be the end user’s task to select the
necessary AMP each time and restart the NC for activation.
The following features can be defined for each AMP:
- number of processes and related characterizations
- number of axes for each process and related characterization
- process variables
- logic interfacing variables (PLUS Variables)

APPLICATIONS BY MACHINING CENTRE MANUFACTURER

Any Applications by the Machining Centre Manufacturer which can be installed on the machining
centre NC are described below
- CMSKMG : this application attends to the serial interface between PLC and spindle Inverter.
It is characterized by the CMSKMG.IMP and CMSKMG.CFG files. In particular the CMSKMG.IMP file
defines the number of the Inverter, the number of electrospindles, the number of tool magazines,
the number of tools and the related coupling of each head.
Also the Machining Centre Manufacturer Applications residing on the PC OFFICE (Els Manager, Tool
Manager,…) use this information.
- CMSRST : application for resetting the electrospindle life, when they are replaced.
- CMSCON : application used for triggering the other applications.

The latest versions of the CMSKMG application are provided with improved diagnostic functions.
In this connection the diagnostic file F:\CMSKMG\CMSKMG.LOG has been provided, where a
certain number of signals from the CMSKMG.EXE application is stored. This number depends on
the value of the #DEB parameter present in the file CMSKMG.CFG, which can adopt the following
values:
#DEB 0 : Minimum signal level (default)

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#DEB 1 : Medium signal level

#DEB 2F: Maximum signal level with output on file CMSKMG.LOG
#DEB 2S: Maximum level with screen output (subject to assignment of video resource to
the CMSKMG.EXE application)

N.B.: folder E:\OEM\AMP1 contains the OEM_CONF.TXT file. This file defines the priority levels
and the video resources associated with the various applications.
By default the video resource is assigned to CMSCON application.
Should any problems arise with the spindle, it is possible to assign the video resource to the
CMSKMG application, to display some additional information which might turn useful during the
diagnostic phase. After making the changes prompted below it is necessary to recompile the AMP
and restart the NC for their acquisition.
Video resource to CmsCon (default) Video resource to CmsKmg
TI 127 512 0 CMSKMG.EXE TI 127 512 1 CMSKMG.EXE
* *
TQ 10 2 TQ 10 2
SM 1 1 SM 1 1
TI 129 512 1 CMSCON.EXE TI 129 512 0 CMSCON.EXE
It is advisable to restore the default configuration any way (#DEB 0 and video resource to the
CMSCON.EXE application) as sending messages implies a waste of extra time at any rate.

WIN FOLDER
Inside the WIN folder the following files can be found:
- CANBUS line configuration file: CANBUS.DBM and CANBUS.RMP
- PLC message file:
-WINPLUS.ASC (former PLC versions)
-ITA.ASC, ING.ASC, FRA.ASC …… (new PLC versions)
-Initializzation/configuration files for the PLC:
-INITVAR
-INITBANC
-INITZERO
-INIT...

-(WINPLUS.DES is created by the NUMERICAL CONTROL automatically)

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PLC STRUCTURE

The figure below shows an example of PLC application in WinPLUS environment.

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As illustrated by the figure below the PLC is structured into more modules: configuration modules
(CicloPLC.res), variable definition modules (Varxxxx.gvl), code definition modules (xxxx.st) and
other auxiliary modules (constant definition, structure definitions, functions, functional blocks and
various libraries).
In particular:
- CicloPLC.res : lists all the tasks of the PLC project
- VarInOut.gvl : lists the definitions of all I/O’s of the PLC project
- VarMsg.gvl : lists the definitions of all messages of the PLC project
- VarMac.gvl : lists the definitions of the main variables of the machining centre in hand
- VarCom.gvl : lists the definitions of the standard variables shared by all the PLC projects
- Fast.st, Assi.st, Proc.st, Driv.st, Zero.st, Funz.st: these are the main program blocks

VARIABLE NOMENCLATURE
The nomenclature of variables has been the target of a great effort of standardization, so as to
simplify the understanding of the various projects. The following tables describe the conventions
adopted.

TABLES OF SYMBOLS FOR I/O SIGNAL NOMENCLATURE

Convention adopted for machine I/O nomenclature. SYMBOL

INPUTS

Derivative, generic, … INP

Flow switch FL

Circuit breaker QF

Motor-protective circuit breaker QM

Braking resistance RR

Selector SA

Button SB

Luminous button/selector SH

Level sensor SL

Pressure sensor SP

Position sensor SQ

Rotation sensor SR

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Temperature sensor ST

Thermostat TR

OUTPUTS

Derivative, generic, … OUT

Indicator light, lamp, HL

Instantaneous relay KA

Power contactors KM

Electromagnetic brake YB

Solenoid valve YV

TABLE OF SYMBOLS FOR GLOBAL VARIABLE NOMENCLATURE

Legend: xxxx Name of block where the memory is set
y System memory initials (S or M)

VARIABLE RANGE SYMBOL

VOLATILE MEMORIES 1 BIT 0÷1 MM_xxxx

VOLATILE MEMORIES 8 BIT BYTE 0÷255 MB_xxxx

VOLATILE MEMORIES 16 BIT WORD (UNSIGNED) 0÷65535 MW_xxxx

VOLATILE MEMORIES 16 BIT INT (SIGNED) -32768÷32767 MI_xxxx

VOLATILE MEMORIES 32 BIT DOUBLE WORD (UNS.) 0÷294967295 MDW_xxxx

VOLATILE MEMORIES 32 BIT DOUBLE INT (SIGNED) -2147483648÷2147483647 MDI_xxxx

VOLATILE MEMORIES 64 BIT LONG REAL floating point 64bit precis. MLR_xxxx

VOLATILE MEMORIES TIME MT_xxxxx

RETENTIVE MEMORIES 1 BIT 0÷1 RM_xxxx

RETENTIVE MEMORIES 8 BIT BYTE 0÷255 RB_xxxx

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RETENTIVE MEMORIES 16 BIT WORD (UNSIGNED) 0÷65535 RW_xxxx

RETENTIVE MEMORIES 16 BIT INT (SIGNED) -32768÷32767 RI_xxxx

RETENTIVE MEMORIES 32 BIT DOUBLE WORD (UN.) 0÷294967295 RDW_xxxx

RETENTIVE MEMORIES 32 BIT DOUBLE INT (SIGN.) -2147483648÷2147483647 RDI_xxxx

RETENTIVE MEMORIES 64 BIT LONG REAL floating point 64bit precis. RLR_xxxx

VOLATILE MEMORIES 1 BIT NC 0÷1 yM_CN

VOLATILE MEMORIES 8 BIT NC BYTE 0÷255 yB_CN

VOLATILE MEMORIES 16 BIT NC WORD (UNSIGNED) 0÷65535 yW_CN

VOLATILE MEMORIES 16 BIT NC INT (SIGNED) -32768÷32767 yI_CN

VOL. MEMORIES 32 BIT NC DOUBLE WORD (UNS.) 0÷294967295 yD_CN

VOL. MEMORIES 32 BIT NC DOUBLE INT (SIGNED) -2147483648÷2147483647 yDI_CN

VOL. MEMORIES 64 BIT NC LONG REAL floating point 64bit precis. yLR_CN

TABLE OF SYMBOLS FOR GLOBAL VARIABLE NOMENCLATURE (VOLATILE ONLY)

VARIABLE RANGE SYMBOL

MEMORIES 1 BIT 0÷1 LOC_MM

MEMORIES 8 BIT BYTE 0÷255 LOC_MB

MEMORIES 16 BIT WORD (UNSIGNED) 0÷65535 LOC_MW

MEMORIES 16 BIT INT (SIGNED) -32768÷32767 LOC_MI

MEMORIES 32 BIT DOUBLE WORD (UNS.) 0÷294967295 LOC_MDW

MEMORIES 32 BIT DOUBLE INT (SIGNED) -2147483648÷2147483647 LOC_MDI

MEMORIES 64 BIT LONG REAL floating point 64bit precis. LOC_MLR

MEMORIES TIME LOC_MT

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NOTES AND EXAMPLES

LOCAL VARIABLES
The LOCAL variables differ from the GLOBAL variables in that they can be used only in the module
they are defined for. To distinguish them from the GLOBAL variables the programming department
decided to prefix the variable format type with the string “LOC_” but without indicating the name
of the block xxxx (as they are defined and used always in the same block).
Examples: LOC_MW_RisultatoConversione , LOC_MM_ConversioneInCorso.

CONSTANT
With WinPlus it is advisable to use some symbolic values in the various computational expressions,
i.e. some CONSTANTS, instead of absolute values whose meaning is not easily grasped.
Generic constants defined in the VarCom.gvl module:
KI_PROCESSO1 : INT:= 1 ;
KT_10MS : TIME:= T#10ms ;
Specific constants defined in the VarAssi.gvl module:
KI_ASSI_NUM_BIT_FEED_OVR : INT:= 5 ;
KI_ASSI_NUM_BIT_SPEED_OVR : INT:= 4 ;

NAME OF VARIABLE
Each name of variable is made up by the variable type, the name of the block (with exceptions)
where the variable is set and by a very concise description. The meaning of the action must refer
to logic state 1 (TRUE).
Exceptions: the name of the block does not need to be indicated in case of LOCAL variables,
system variables, I/O signals and is omitted in case of variables indicating M/S/T functions.
With WinPlus the name of a variable can be maximum 32-character long.
Per costruirlo unire fra loro TUTTE le parole della relativa descrizione, scrivendo in maiuscolo
l’iniziale di ciascuna parola tranne il tipo di variabile che va scritto interamente in maiuscolo
utilizzando il carattere “_” come separatore.

Ulteriori convenzioni vengono utilizzate per alcuni tipi di variabili utilizzate ad esempio per la
decodifica di softkey , per i messaggi , per i parametri formali delle funzioni o per variabili
rappresentanti maschere di bit.
Negli esempi e nelle note che seguono sono indicati tutti i casi previsti.

Esempi :
Indirizzo (opzionale) Nome Variabile: Tipo
M 1004,04 INP_OkModuloEmergenza Segnale ingresso

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M 1010,00 SQ_PortaDxAperta Sensore di posizione

M 1130,03 YV_SoffiatoreUtensile Elettrovalvola
M 1355,00 MM_ASSI_AsseXInMovimento Bit Globale da modulo ASSI.ST
MM_VARI_AuxGestioneZone Bit Globale da modulo ASSI.ST
(senza associazione a variabile
pagina vecchia PLUS)
GW 94 RI_CAMB_UtensileMandrino INT Ritentivo da modulo CAMB
MW 2710 MI_ZERO_MskRichiestaZeroAssi INT Globale da modulo ZERO.ST
S 20,07 SM_CN_ResetProcesso1 Bit di sistema
M 143,05 MSG_CAMBIO_CambioUtInCorso Messaggio
M 3801,05 M21 Funzione M
LOC_MI_Contatore INT Locale

TABELLA DEI SIMBOLI PER NOMENCLATURA ULTERIORI STRUTTURE DATI

Per le convenzioni adottate per la nomenclatura di Funzioni , Temporizzatori , Pulse , ecc . riferirsi
alla seguente tabella:

STRUTTURA DATI SIMBOLO ESEMPIO

FUNZIONE F F_EseguoSomma

BLOCCO FUNZIONE FB FB_DatiUt.

Par. d’Ingresso Funzione FNI_MI FNI_MI_Addendo1

Par. d’uscita Funzione FNO_MI FNO_MI_Risultato

Timer tipo TON TimerTon TimerTon_RitardoInitMotori

Timer tipo TOFF TimerToff TimerToff_Spegnimento

Timer tipo TP TimerTp TimerTp_Soffiatore

Pulse salita Pulse_Up PulseUp_PrimoPowerOn

Pulse discesa Pulse_Down PulseDownResetCnProc1

Struttura Dati STR_ STR_MOVCU_ArrayCanPhaseCu

Per ulteriori approfondimenti consultare il Manuale OSAI “WinPLUS: Manuale di Programmazione”

(cod.Osai 45006877B).

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DEBUG PLC

Una volta scritto il codice è necessario compilare il progetto prima di trasferirlo nel CN (download).
Per compilare il progetto cliccare sull’icona indicata in figura. Con alcune versioni di WInPLUS
l’operazione di compilazione necessita della relativa chiavetta HW.

Nel caso di errori di compilazione provvedere alla relativa correzione.

Per esempio:

In questo caso cliccando due volte sulla prima riga errata nella lista errori è possibile rintracciare
velocemente il punto in cui l’errore è presente. Apportare le correzioni del caso e ripetere
l’operazione di compilazione. Il risultato che si deve ottenere è il seguente:

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A questo punto è possibile scaricare il progetto in macchina cliccando sull’icona indicata nella
seguente figura.

Alla seguente richiesta cliccare su “Si” come indicato in figura:

Ignorare le eventuali segnalazioni di Errore / Warning che vengono emesse al termine

dell’operazione di Download. Verificare che l’operazione si concluda con la scritta “… download
finished” come indicata nella figura seguente:

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RICERCHE VELOCI
I seguenti comandi sono particolarmente utili nelle fasi di debug PLC e diagnostica:
a) “Cerca in files” ⇒ ctrl+i
b) “Vai alla linea” ⇒ ctrl+g--

ULTERIORI OPERAZIONI DI DEBUG

Esistono inoltre i seguenti strumenti di debug che consentono di eseguire operazioni di diagnosi e
debugging più complesse e nel caso di utilizzo dei breakpoint anche pericolose. Il relativo utilizzo è
riservato a personale qualificato.
a) Watchpoint
b) Watch List
c) Breakpoint

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BACKUP & RESTORE CN

It is possible to save all the files which are on the NC at the same time, without the need to store
them separately.
Please note that the PLC project is on the PC OFFICE and should be saved separately as for all
other applications which are on PC OFFICE.

BACKUP CN
The following procedure describes the steps to be done to save all the data of the NC on the PC:

You must start from the condition

1. CN activated
2. Machine in Emergency stop

• Press UTILITY

• Press BOOT CONTROLLER

• Press MODE

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• Press SETUP

• Press BOOT

• Press REBOOT

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• Compare il messaggio “ARE YOU SURE YOU WANT TO BOOT THE CNC”
• Cliccare su YES

Wait for the complete reboot of the system

• Wait until you see the message “CNC IS IN SETUP MODE”

• Press SECURITY shown in figure:

• Press BACKUP and specify the path and name of the backup to be created:

• Create a new folder “BCKxxxx” (xxxx represents the serial number of the machine).

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• Open the folder you just created, specify the file name and press SAVE

• Select “All the control” tag and press START:

• Wait for the end of the Backup operation, until it is shown the message “Operation
completed successfully!”

• Close the SETUP interface:

Press FILE
Press EXIT

• Into BOOT CONTROLLER interface, select MODE then press NORMAL to restart the CN in
standard mode and resume normal operation of the machine:

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• Press BOOT, then REBOOT

• Press YES and wait the end of the operation.

• Restart the machine.

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RESTORE CN
The following procedure describes the operations to load all the data from the PC to the NC:
Requerements:
1. CN activated
2. Machine in Emergency stop

• Press UTILITY

• Press BOOT CONTROLLER

• Press MODE

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• Press SETUP

• Press BOOT

• Press REBOOT

• It is shown the message “ARE YOU SURE YOU WANT TO BOOT THE CNC”
• Press YES

CN runs the Reboot.

• Wait until it is shown the message “CNC IN SETUP MODE”

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• Select the SECURITY shown in figure:

• Press RESTORE, select BROWSE… e indicare il percorso ed il nome del file di backup da
ripristinare.
• Select the three options “System area”, “OEM area”, “User area”:

• Press START and wait for the completion of recovery operations CN, which is specified by
the message “Operation completed successfully!”

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• Close SETUP interface:

Press FILE
Press EXIT

• In the BOOT CONTROLLER interface, select MODE, then press NORMAL to restart the CN
in standard mode and resume normal operation of the machine:

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• Press BOOT then REBOOT

• Select YES and wait the end of the process.

• Shut down and restart the machine.

RIFERIMENTI

Documento: install Win e CN v22.doc

Documento: WnBBck.doc
Documento: WnBRst.doc

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