CIROS Festo CP-System User Manual

Based on CIROS v7.1.7

Can be used for v6.4.6 and v7.0

with few variations.

© 2022 - Festo Didactic SE. BD-AR \ Hoi Yee Cheang 01.12.2022

Content
1. Introduction to CIROS (→) 2. Introduction to CIROS Model (→)

• Overview • Collaborative Working

• Installation • Model’s Structure
• License • Elements and Coordinate Systems
• Application Scenarios • Create a Model
• Help Menu • Window’s Layout
• Keyboard Shortcuts
• Toolbar
• Options Setting
• Window’s Size • View and Edit Mode
• Standard Views
• View Used when Creating CIROS Model
• Snapping into Place
• Floor and Background
• Import and export data
• Teacher mode
• Simulation Control in Model Window

2
Content
3. Introduction to Festo CP-System (→) 4. CP-System Model Libraries (→)

• Building Blocks • Open Model Libraries Window

• Product • Model Library Festo CP System
• Terms and Definitions • Configuration in Properties Section CP System
• Standard Part Numbers • Sources and Sinks
• Group and Utilities • Adding New Libraries to CIROS
• Carriers
• Resources and Buffers

3
Content
5. Virtual Commissioning with MES4 (→) 6. Virtual Commissioning with Soft PLC (→)

• Steps to Virtual Commission with MES4 • Scenario Overview

• Steps to Virtual Commission with FactoryViews • Process Summary
• Steps to Virtual Commission with Robotino • Preparing a CIROS Model
• Synchronise CIROS Parts in Storage with MES4 Buffers • Starting a PLCSIM Instance
• Running CIROS and MES4 on Different PCs • Creating the Hardware Configuration and IO Tags in TIA Portal
• Running CIROS and Fleet Manager on Different PCs • Configuring the Interface
• Terms and Definitions in MES4 • Common Issues
• MES4 Communication Interface • Remote Connection between CIROS and PLCSIM Advanced
• Terminology in MES4 Messages
• MES4 Service Requests
• Festo MES4 Interface
• Use Case: Update Resource Status with MES Controller
• Message Request from CP System to MES4
• MES Communication Flow Chart
• Message Request from CIROS to Fleet Manager

4
Content
7. Simulation (→) 8. Python (→)

• Simulation Kernel • Python in Model Libraries

• Reduce Simulation Computing Requirement • Python Installed but Not Working
• Code Sequence Trace • Python Scripts in CIROS
• Visualising Sensor Data • Built-In Function List
• Data Logging • CP System Construction Helper
• Simulation Control in CP System • Use Case: Common TCP/IP Communication

5
Content
9. OPC UA Interface (→) 11. Robot Programming (1) (→)

• CIROS as OPC UA Client • Mitsubishi Industrial Robot

• Layout and Windows
• CP-F-RASS
• Steps to Configure CP-F-RASS for Simulation
• Steps to Simulate CP-F-RASS
• Simulate Real Robot Program in CP-F-RASS Model
• CP-F-RASS Robot Programming
• Move Robot Manually
• Mount and Release a Gripper Manually
• TCP Tracking
• View TCP Coordinate
• Robot Workspace
• Collision Detection
• Connect to Robot Controller
• Online Information from Robot Controller

6
Content
11. Robot Programming (2) (→) 12. VR (→)

• Create / Load Robot Controller Backup • Setting Up VR Glasses

• Upload / Download Robot Programs
• Interact with Model
• Online Teach-In
• Get Actual Robot Data with Built-In Python Function

7
Content
13. Advanced (→) 14. Troubleshooting (→)

• Move I/O Address • External document “CIROS-CP_Troubleshoot_EN_v7.1_xxxxxx.pdf ”

• Export as High-Resolution Images
• Multiple View Windows
• CIROS Starter
• Model Analysis
• CIROS Part Number for CP System
• Steps to Create Own Part
• Steps to Create Own Model Library
• Steps to Create Own Virtual Machine Communicating with MES4

8
Introduction to CIROS
Overview
CIROS – Computer Integrated RObot Simulation

• Powerful, kinematic real-time 3D simulation

• Time-discrete simulation kernel (update every 40ms)
• Large model library: not only CP Lab / Factory, but also >1000 robots
from various manufacturers
• CAD import for user-defined modules / kinematics
• Several interfaces, e.g. to MES4, Fleet manager, Matlab, Python, VR
glasses, Mitsubishi robots, …
• User interaction during simulation
• Collision analysis
• Fault injection / simulation
• PLC and robot programming
• Online help with introductory examples

10
Overview
Studio vs. Education

• CIROS Studio • CIROS Education

• Full version including all features • Limited functionality
• Designing and saving models from scratch • Already existing models can be analyzed & modified, but not
• RCI explorer interface to Mitsubishi robot controllers saved
(download/upload of programs, individual step tracking) • No RCI explorer interface to Mitsubishi robot controllers
• Fits perfect for preparation of teaching scenarios to be • Fits perfect for scenarios, in which CIROS studio models have
analyzed by students to be opened, analyzed, and modified only

11
Overview
Language packs & software releases

• CIROS Studio and Education are two different software

products.
• Depending on the license key one is allowed to start CIROS
Studio and/or Education.
• Installation of different CIROS releases & language packs on a
single PC possible.
• Unfortunately, the desired language must be set during
installation (there is no option to change the language during
runtime) .

12
Overview
Hardware requirements

• Either USB port for USB dongle or network access for server-based licensing
• Officially supported operating system: Windows 10

• Hardware requirements
• High-performance CPU, i.e. Intel i5/i7
• At least 8 GB main memory
• At least 4 GB SSD memory
• NVIDIA graphics card with OpenGL 4.5 support and 4 GB dedicated memory

• When using CIROS in combination with other software (e.g., MES4, PLCSIM Advanced) two screens are highly recommended!
• It is also possible to run CIROS and other software (e.g., MES4, PLCSIM Advanced) on different PCs

13
Installation
• Open Start.exe and select CIROS Applications.

14
Installation
• Select either CIROS Studio or CIROS Education to be installed.

15
License
License is managed by CodeMeter.
List of USB dongles currently attached to the system.
2

16
View local licenses in CodeMeter WebAdmin
Option 1 Option 2

Right mouse button opens context menu.

17
CodeMeter WebAdmin
Note: All CIROS related licenses should be placed in the same container.

List of licenses
stored on the
attached USB
dongle.

18
Licenses from Server
Allowing CodeMeter WebAdmin to act as a server.

19
Licenses from Server
Connecting to a CodeMeter WebAdmin server. (1)

20
Licenses from Server
Connecting to a CodeMeter WebAdmin server. (2)

3
4

Enter IP address of the PC acting as a server.

21
Licenses from Server
Connecting to a CodeMeter WebAdmin server. (3)

22
Licenses from Server
Connecting to a CodeMeter WebAdmin server. (4)

Refresh to see the available servers.

23
Application Scenarios

Virtual Commissioning
OPC UA
Process Optimisation
Large Classrooms
PLC Programming
Python

Virtual Reality

Robotics
CAD Import

Data Generator for Data Analytics

Video Export
Fault Injection

24
Application Scenarios
Process optimisation

• Assume following process: Front cover → Measuring → Back cover → Pressing → Heating → Delivering
• Which of the two configurations below is more efficient?
Heating Pressing Delivering Heating

Delivering Pressing

Front
Back cover cover Back cover
Measuring

Front Measuring
cover

25
Application Scenarios
PLC programming (example with Siemens PLC)

EasyPort

Real PLC

PLC programm EzOPC

Soft PLC

26
Help Menu
• Detailed help system with a couple of introductory examples, but not focusing on CP Lab / Factory explicitly.
2

27
Keyboard Shortcuts
SHIFT + left mouse button Move user perspective in view mode
CTRL + left/right mouse button Rotate user perspective in view mode
+/- Zoom in / zoom out
V/H Front / rear view
A Top view
R Right view
L Left view
SHIFT + O Full screen
F5 Start / stop simulation
CTRL + F5 Reset simulation
CTRL + E Toggle between view (default cursor) and edit mode (crosshair cursor)
CTRL + . / CTRL + , Rotate selected object by +/-90° in edit mode
CTRL + T Show model explorer
CTRL + F9 Compile robot / PLC programs
CTRL + SHIFT + M Show model libraries

28
Options Setting

• CIROS has two option settings, application options and model options. There are for different configurations
• Application options configure the whole CIROS application, regardless of the models.
• All changes made in model options are only applied to the active model.

29
Application Options
File → Application options

• Define data import and export

• General display settings
• Frequently used to reduce computational load.
• Editor settings
• Warning options for modelling and transport
• ORL
• Position and paths
• Programming tools settings
• VR devices configuration
• Workspaces

30
Model Options
Settings → Model options

• Collision detection
• Model display settings
• Background
• Floor
• Sensors
• Etc.
• Fault simulation in teacher mode
• Interfaces
• MES4
• Fleet Manager
• Data logging
• Model explorer settings
• Modelling
• Online management for Mitsubishi robots
• ORL
• Overlays
• Model Simulations
• Video recorders

31
Where to look for the options?
• Structure and elements of models
• Modell Explorer: Modelling → Model Explorer or Ctrl+T
• Often used

• Properties of elements in the model

• Properties: Modelling → Properties or Alt+Enter
• Assistant
• For example Settings → Collision detection
• Often used

• Properties of model
• Model options: Settings →Model options or Ctrl+I
• Used fairly

• Properties of CIROS program

• Application options: Files → Application options or Ctrl+Shift+I
• Seldom used

32
Window’s Size
• Windows size for Application Window and Modell Window can be adjusted.

33
Introduction to CIROS Model
CIROS Model
• Preliminary remark: Each CIROS model not only consists of the
modx/ini files but also the folders CF and Textures, storing the
internal PLC programs and textures
• It is highly recommended, to store each CIROS model in a
separate folder!
A CIROS project folder:
• Important: Do not copy the modx/ini files only, but the entire
folder containing the subfolders CF and Textures, too!

35
Collaborative Working
• Several users can work on the same model at the same time.
• When a user changes the model, other users will receive a notification.
• However, simultaneous changes and changes that crossed over time cannot be merged together.

36
Model’s Structure
Elements in a model Model
• Structures of elements Object
• Model / Environment
• Objects: Logical unit Section
• Sections: Static body
• Hulls: Geometries Hull

• Positions based on coordinate system

• Hulls
• Geometric primitives
• Box,sphere, etc.
• Polyhedron
• Vertex, Facet

37
Model’s Structure
• Objects in the structure tree
• Placed on the highest hierarchy in the model or Model
• Placed under an object
Object
• Object’s nomenclature
• Parent object: superordinate object Object
• Child object: child of a parent object

• Usage
• For a clear structure
• Definition of static assembly

• Moving child objects

• During modelling: always
• During simulation: only when the object is an object assembly
• Select object → right click → Edit → Assembly

38
Elements and Coordinate Systems
• Different coordinate systems, each might has same or different origins
• World : based on world coordinate system
• Object : based on coordinate system of the parent object
• Section : based on coordinate system of the section it belongs to
• Hull : based on coordinate system of the hull

• In model window, origin of three axes of coordinate system are shown in different colours.
Z

39
Create a CIROS Model
• Recommended way of defining a new CIROS Model
1. Choose FILE → New → Model assistant
2. Specify the model’s name and enable Create a subfolder with the same name as the model.
3. Important: Do not select a robot, these ones are not the ones integrated within CP Lab / Factory! Choose Empty model instead!

2 3

40
Window’s Layout

Model explorer View window

Model vs. real

time
If the model time is
Properties printed in red, the
window system is not able
Available model to perform the
libraries simulation in real
time.
41
Toolbar can be configured

42
View and Edit Mode
View mode Edit mode

• Change user perspective onto scene • Place, move, rotate objects within scene
• Default cursor: • Crosshair cursor:

43
Standard Views

44
Standard Views

Default setting Front view Rear view

Top view

Left side view Right side view Bottom view

45
View Used when Working with CIROS Model
• With respect to the z-axis all CP Lab / Factory modules within
the library have been prepared in such a way that
• Conveyor belts, CNC milling stations, robot assembly
stations, warehouses, and Robotinos are placed on the floor
(z = 0mm)
• Carriers, deflections, sources, sinks, and application modules
flush with the conveyor belts’ upper edges (z = 975mm)

• Important
• Switching to Top View ensures that the z-values remain
constant when moving components within the scenery!
• Snapping into place of modules works well in Top view only!

46
Snapping into Place
• When placing application modules onto conveyor belts, it is not
necessary to adjust them as precisely as possible.
• Just putting the phrases Application, CPLab, Modul, etc. on top
of each other is all one has to do!
• Same holds for mounting deflections, docking kits, and so on.

47
Floor and Background
• Floor can be activated or deactivated.
1. Right click in view window.
2. Check or uncheck Floor.

• Floor’s size and muster can be adjusted.

• Open Settings → Model options → Display → Floor.

• Background can be adjusted.

• Open Settings → Model options → Display → Background.

48
Import Data
• It is possible to import a model from CAD data by selecting File → Import.
• Supported formats are as follow:
• 3ds Max
• AutoCAD DXF
• Autodesk
• Blender
• Collada
• IGES
• PointCloud
• STEP
• STL
• VRML
• Wavefront Object

49
Export Data
• It is possible to export a model or selected objects in the model to CAD or picture.

1. To export a whole model, in Model Explorer, select Objects. To export objects in model, select the objects in Model Explorer.
2. Click File → Export.

• Supported export formats are:

• AutoCAD
• For viewing in a web browser (HTML)
• PNG
• IGES
• POV-Ray scene description
• RT toolbox file
• STEP
• STL
• VRML
• Windows bitmap
50
Teacher Mode
• Teacher mode can be activated to configure fault simulation in “Fault Setting “ and “Fault Log” windows.
• Extras → Fault Simulation → Teacher Mode
•

• Password for Teacher Mode is “didactic”.

51
Simulation Control in Model Window
• Simulation control buttons can be shown in model window.
• This is to allow simulation control in full screen mode or in VR.

1. Go to “Settings → Model option”.

2. Select “Display → Handling”.
3. In section “General”, activate “Show simulation control”.
4. Click on “ok”.

52
Introduction to Festo CP-System
Building blocks Module / Ressource

Resource Application

Carrier

Base module

54
Building Blocks
Carrier and product

+ +

Carrier Palette Product

Product
Palette (Smartphone)
Carrier

55
Product (Smartphone)

Back cover
Covers are available in
four colours

Inlay (optional)
- PCB
- Fuses

Front cover
- Slot for screen
- An opening for Button
- Able to drill holes for screw thread
56
Terms & Definitions
Parts External production part Carrier

• Set of all objects, except Robotinos, that are moving around

within a CP Lab / Factory.
• Parts get identified by a unique part number (PNo).
• Six different subclasses. Production part Box

External production parts Parts not produced by CP Lab / Factory

Production parts Parts produced by CP Lab / Factory
Boxes Transport workpieces from one production facility to
another
Pallets Mounted on top of the carriers
Undefined Pallet
Carriers Move (external) production parts on the conveyor
belts.
Undefined Containing all unknown parts or objects, typically
used to represent faulty parts.

57
Standard Part Numbers
Supported part numbers

25 Pallet • Supported part numbers are parts that can be booked into a
31 Carrier high-bay warehouse at simulation time t=0s.
110 / 109 / 108 / Raw material front cover black / grey / blue / red • All other part numbers – in particular user-defined parts – can
107
be generated and stored into a high-bay warehouse during
111 / 112 / 113 / Back cover black / grey / blue / red
production, but not replicated in a warehouse at simulation
114
startup at t=0s.
210 / 310 / 410 / Front cover black / grey / blue / red
510
x11 / x12 / x13 / Front cover in black / grey / blue / red including
x14 (x = 2, 3, 4, 5) PCB / front fuse / rear fuse / both fuses
1y11 / 1y12 / 1y13 Front and back cover in black / grey / blue / red
/ 1y14 (y = 2, 3, 4, including PCB / front fuse / rear fuse / both fuses
5)
26 / 120 / 130 Unknown workpiece / PCB / fuse

58
Standard Part Numbers
Some examples

Part number 412 Part number 513 Part number 1214 Part number 109
(blue, PCB, front fuse) (red, PCB, rear fuse) (black, both fuses, back cover) (grey, raw material front cover)

59
Groups and Utilities
• Groups define sets of parts somehow belonging to each other.
• Besides the list of parts belonging to a group each group also Almost Final Products
contains a unique ID and a description.
• There is no restriction on the number of different types of parts
a group consists of.
• Parts can be attached to an arbitrary number of groups or not
attached to any group at all.
• Typically, groups are used to define zones and restrictions wrt.
buffer positions of a high-bay warehouse.
• Utilities defines a special subclass or group of parts, containing
all carriers, boxes, and pallets, which are the ones that are
responsible for transport purposes.

60
Carriers
• In CIROS two different kinds of carriers are supported
• CP-F-CARRIER: Carriers without Pallets

• CP-L-CARRIER: Carriers including Pallets

• Carriers without Pallets must be used in cases in which a CP Factory high-bay warehouse is part of the CIROS model, since the
workpieces will be stored and released together with pallets in this situation!
• In all other cases Carriers including Pallets should be used
• Rule of thumb according to the number of carriers used within a CIROS model: One carrier per conveyor belt.

61
Resources and Buffers
• Resources are the production facilities (modules) of the CP Lab
/ Factory.
• Each resource is represented by a unique ID.
• Periodically, each resource sends a status update to MES4 and
gets process data back when initiating a corresponding service
call.
• Robotino is a special kind of a mobile resource.
• Some resources contain buffers, like the high-bay warehouse,
the robot assembly station, Robotinos, and the branches.
• Each buffer consists of at least one buffer position to store
parts, one per buffer position.
• MES4 could be configured in such a way that, based on zones
and restrictions, buffer positions are allowed to store specific
types of parts only.

62
CP-System Model Libraries
Open Model Libraries Window
Modelling → Model libraries

64
Model Library Festo CP System
• There are four groups containing CP Lab / Factory modules

Name Description

CP-Application Application modules

CP AR AR Marker for Festo Didactic Augmented Reality

CP Factory CP-Factory based modules and stations

CP Lab CP-Lab based modules

CP Mobile Robots Robotino related modules

CP-Models CP-Lab standard systems with configured

MES4 v1 database

• For each module there is a brief description and a tiny image.

65
Model Library Festo CP System
CP Application

Module Description
CP-AM-CAM Camera inspection
CP-AM-DRILL Drilling
CP-AM-HEAT Heating tunnel
CP-AM-iDRILL Drilling module with own PLC
CP-AM-iPICK Pick by light with own PLC
CP-AM-LABEL Labelling printer
CP-AM-MAG_BACK Back cover magazine
CP-AM-MAG_FRONT Front cover magazine
CP-AM-MANUAL Manual working place
CP-AM-MEASURE Analog measurement
CP-AM-MPRESS Muscle press
CP-AM-OUT Workpiece output
CP-AM-PRESS Pressing
CP-AM-TURN Workpiece flipping

66
Model Library Festo CP System
CP AR

Module Description
CP-AR-GUI CP-AR QR-Code to the AR server.

67
Model Library Festo CP System
CP Factory

Module Description
New
CP-F-ASRS20-B Automated Storage Retrieval System for boxes
CP-F-ASRS32-P Automated Storage Retrieval System for parts and pallets
CP-F-BRANCH Branch base module
CP-F-BUF-B New Manual working place with automated box transfer
CP-F-BUFROB-B New Part transfer between box and CP-Factory line with robot
CP-F-BUFROBM-B New CNC milling application attached to robot and box transfer
CP-F-BYPASS CP-Factory base module with bypass belt
CP-F-CARRIER 15 carriers for CP-Factory base modules without pallet
CP-F-DEFLECTION180 Passive 180° deflection
CP-F-FEEDROBM CNC milling application attached to robot and CP-F linear
CP-F-LINEAR CP-Factory base module with two parallel conveyor belts
CP-F-RASS Robot assembly station
CP-F-SINK Sink to remove carriers, pallets, workpieces
CP-F-SOURCE Source to generate carriers, pallets, workpieces

68
Model Library Festo CP System
CP Lab

Module Description
CP-L-BRANCH Branch base module
CP-L-CARRIER 15 carriers for CP-Lab base modules with pallet
CP-L-CONVEYOR CP-Lab base module with a conveyor belt
CP-L-DEFLECTION90 Passive 90° deflection
CP-L-iASRS12-W Automated Storage Retrieval System for parts
CP-L-SINK Sink to remove carriers, pallets, workpieces
CP-L-SOURCE Source to generate carriers, pallets, workpieces

69
Model Library Festo CP System
CP Mobile Robots

Module Description
CP-MR-B New
Robotino for boxes
CP-MR-C Robotino for carriers
CP-MR-DOCK Docking kit to be mounted on branches
to enable (un)docking maneuvers by a
Robotino
CP-MR-PARK New
Robotino parking position

70
Model Library Festo CP System
CP-Models

Module Description
CP Lab 404-1 Standard CP Lab system with four stations and configured MES4 v1
1. Front cover magazine
2. Analog measurement
3. iDrill
4. Workpiece Output
CP Lab 406-1 Standard CP Lab system with six stations and configured MES4 v1
1. All modules in CP Lab 404-1
2. Back cover magazine
3. Pressing
CP Lab-408-1 Standard CP Lab system with six stations and configured MES4 v1
1. All modules in CP Lab 406-1
2. Pick by light
3. Labelling
CP Lab 410-1 Standard CP Lab system with six stations and configured MES4 v1
1. All modules in CP Lab 408-1
2. Camera inspection
3. Turning
SAP4School Model for virtual commissioning of SAP4School

71
Configuration in Properties Section CP System
• For almost all components there is a section CP System as being part of the
corresponding Properties menu.
• Represents the options that can be defined at the HMIs of a real CP Lab / Factory
• MES ID
• Traffic jam control
• Energy saving (stopping the belts whenever possible)
• Behavior of branches
• Additionally, one can configure some CIROS internal parameters not available on a
real CP Lab / Factory.

72
Configuration in Properties Section CP System
Define MES ID (1)

• MES ID = 0 → Default mode without using MES4

• MES ID > 0 → MES4 mode

• Note, that the default mode of CIROS is not equal to the default
mode of a real CP Lab / Factory!
• If the MES ID of at least one component is greater 0, running
the CIROS simulation without MES4 results in an error
message!

73
Configuration in Properties Section CP System
Define MES ID (2)

• Typically, MES ID is defined with one of the two ideas below:

• Based on the MES IDs of a similar real CP Lab / Factory.
• According to the default process to be performed, starting
with MES ID = 1 for the component which is executing the
first step of the process.

• Constraints
• MES IDs must be unique throughout the entire model .
• Each MES ID must be greater 0.
• Definition of IDs within CIROS and MES4 must match each
other.

74
CP-AM-iDRILL
Configure x-axis linear drive

1. Configure axis lower limit, upper limit and maximum velocity. 2. It is possible to see the position of the drill bit in model window.
1. In Model Explorer, select CP-AM-iDRILL → Mechanik. 1. In Properties, select Axes → DH parameters.
2. In Properties, select Axes → Axis parameters. 2. By dragging the scale XAchse at bottom, the drill bit will move accordingly
3. Adjust Lower limit, Upper Limit and Max. velocity.

1.3

1.1

1.2
2.1

2.2

75
CP-AM-iDRILL
Object Mechanik (1)

• The object Mechanik has type Mechanism. It is a double acting

cylinder.
• Object type double acting cylinder in CIROS has following
attributes, which can be assigned to I/O. By default, following
attributes are connected.
• The attributes can be viewed in CP-AM-iDRILL → Mechanik →
Section XAchse → Properties → Mechanism.

Note: Terms might varies in different language.

76
CP-AM-iDRILL
Object Mechanik (2)

• It is possible to assign own I/O to the attribute.

1
• In this example, An analog output ActualXPosition is assign to the
attribute Actual position.

1. Add a new analog output with name ActualXPosition in object

Mechanik.
2. In Model Explorer, select CP-AM-iDRILL → Mechanik → Section
3
XAchse.
3. In Properties, select Mechanism.
4. In Attribute table, select the row Actual position [output].
5. Click on the drop down list at the bottom, select ActualXPosition.
6. Click Apply. 5

77
CP-AM-iPICK
Configuration in properties section CP System

Property Description
Working time (s) Working time required by the worker
to finish an operation (valid for
CIROS and CIROS/MES4).
Target number Part number of the part to be
replicated by the worker (valid for
CIROS default mode only).

78
CP-AM-MAG_BACK
Configuration in properties section CP System

Properties Description
Automatic Mode In “Automatic Mode” the magazine
will be filled automatically during
simulation.
Colour Workpiece Defines the color of the back covers
stored in the magazine. By enabling
“Manual Override” the user can
specify the color of each individual
cover to be replicated.

79
CP-AM-MAG_FRONT
Configuration in properties section CP System Default Rotated
orientation orientation
Properties Description

Automatic Mode In “Automatic Mode” the magazine will be filled

automatically during simulation.
Colour Workpiece Defines the color of the front covers stored in the
magazine. By enabling “Manual Override” the user
can specify the color of each individual cover to be
replicated.
Workpiece Defines the front cover type, is it a raw plastic
block, front cover without drilled holes or final
front cover.
Percentage Rotated Fault injection option, defines percentage of faulty
Workpieces part filled to the magazine.

80
CP-AM-MANUAL
Configuration in properties section CP System Default Rotated
orientation orientation
Properties Description

Working time (s) Working time required by the worker to finish an

operation (valid for CIROS and CIROS/MES4).
Target number Part number of the part to be replicated by the
worker (valid for CIROS default mode only).
Percentage Faulty Fault injection option. In case the worker must
Fuses replicate workpieces with fuses, one can specify
the percentage of “faulty” fuses assembled (faulty
fuses are highlighted in red) .
Percentage Rotated Fault injection option. Percentage of workpieces
Workpieces placed in a rotated orientation (upside down).

Faulty fuses are

shown in red

81
CP-AM-MEASURE
Configuration in properties section CP System

Properties Description

Measurement Variation Fault injection option, adds some random

“noise” with Gaussian filter to the measured
value.

82
CP-AM-OUT
Configuration in properties section CP System

Properties Description

Automatic Mode In “Automatic Mode” workpieces will be removed

from the ramps automatically during simulation.
Otherwise, one might run into a traffic jam due to
slides full!

83
CP-AM-TURN
Configuration in properties section CP System

Properties Description

Gripper Position Before starting the simulation, one must specify

whether front covers or entire workpieces (i.e., front
& back covers pressed together) should be rotated
upside down.

84
CP-F-BRANCH / CP-L-BRANCH
Configuration in properties section CP System

Properties Description

Traffic Jam Stop carrier if conveyor belt is occupied.

Conveyor Belt Stop conveyor belt while application is running.

Behaviour of Percentage of carriers without an order turning to the

Carrier Shunt right.

85
CP-F-RASS
Configuration in properties section CP System

Properties Description

Traffic Jam Stop carrier if conveyor belt is occupied.

Conveyor Belt Stop conveyor belt while application is running.

Behaviour of Percentage of carriers without an order turning to the

Carrier Shunt right.
Automatic Mode In automatic mode PCBs in the box will be created
automatically regardless of buffer in MES4.
ID for the box If the box is not created by MES, this will be the ID of
the box.
Percentage Percentage of “faulty” fuses assembled by the robot
Faulty Fuses assembly station. Faulty fuses are highlighted in red.

86
CP-MR-C / CP-MR-B
Configuration in properties section CP System

Properties Description

RFM ID Unique ID, mandatory for the Festo Fleet Manager to

get access to a particular Robotino .

Note:
• CP-MR-C stands for Cyberphysical-Mobile Robot-Carrier.
• CP-MR-B stands for Cyberphysical-Mobile Robot-Box.
• RFM stands for Robot Fleet Manager.

87
CP-MR-DOCK
Configuration in properties section CP System

Properties Description

Station ID Unique ID, mandatory for the Festo Fleet Manager to

differ between the various docking positions a
Robotino could dock to within a model.
Dock position Number of conveyor belts available for exchanging
workpieces (always 1 for carrier Robotinos).

88
Sources and Sinks
• Sources and Sinks can be used to dynamically replicate and
remove workpieces during the simulation, either via pushing
the corresponding button or automatically controlled by CIROS.
• There are different versions of sources and sinks, one set to be
applied to CP Lab conveyor belts and one set to be used in
combination with CP Factory components.
• Typically, sources and sinks come into play whenever one
wants to model a single conveyor belt & application module.

89
Sources and Sinks
Remarks

• Depending on the model, sources and sinks may have to be rotated to operate correctly!

Rotated by 180°

Rotated by 90° Rotated by 90°

counterclockwise clockwise

Not rotated

90
Sources and Sinks
Configuration in properties section CP System

Properties Description

Automatic Mode If enabled carriers / pallets / workpieces within the

range of the sink will be removed automatically
during simulation.

91
Adding New Libraries to CIROS
1. Open an already existing model or create a new CIROS model like
shown before.
Note: Model libraries window can only be opened when a CIROS model is opened
or created!
2. Open the model libraries window
• MODELING → Model libraries or
• CTRL + SHIFT +M
3. Click on the right mouse button within the tree view part of the model
libraries to open the corresponding context menu
4. Execute Add folder to list…
5. Select the folder in which the model library to be added is stored and
press OK

92
Virtual Commissioning with MES4
Basic knowledge in Festo MES4 and Fleet Manager is required.
Virtual Commissioning with MES4 Tutorial
MES4 v2 and below

1. Create a new CIROS project.

Video tutorial: 10_CreateNewCIROSModel.mp4
2. Build a CIROS model from model libraries.
Video tutorial: 11_BuildAModelFromModelLibraries.mp4
3. Configure MES4.
Video tutorial: 12_MES4ForCirosModel.mp4
4. Configure CIROS model respective to the MES4 configured.
Video tutorial: 13_ConfigureCirosModelForMES4.mp4
5. Run the simulation
Video tutorial: 14_SimulateAnMES4Order.mp4

94
Virtual Commissioning with MES4 Tutorial
1. Create a new CIROS project.

1. Choose FILE → New → Model assistant

2. Specify the model’s name and enable Create a subfolder with the same name as the model.
3. Important: Do not select a robot, these ones are not the ones integrated within CP Lab / Factory! Choose Empty model instead!

2 3

95
Virtual Commissioning with MES4 Tutorial
2. Build a CIROS model from model libraries.

1. Switch to Top View within the list of views.

2. Open the model libraries.
3. Select all modules needed and add them to the model.
Note: take care, that components properly snap into place.
4. After adding all modules, select each passive deflection and snap it into place again!
5. Depending on the model,
1. Integrate sources and sinks if required.
2. Adjust floor and background.
3. Disable shadow simulation

96
Virtual Commissioning with MES4 Tutorial
3. Configure MES4.

1. According to the CIROS model add all resources in MES4.

Picture source: MES4 v2 or lower
• Application modules and Robotino.
• CP Lab branches (Remark: CP Factory branches are defined implicitly by the MES4 topology) .
• Define the MES4 ID, IP address, type of PLC (i.e. Siemens) of each resource.
• Specify the system’s topology.
2. Start the CIROS simulation and check in MES4 Production Control → Resources whether all resources are available and active.
3. Define all parts that are required by the various work plans.
4. Add work plan(s).
5. In case a high-bay warehouse is part of the model, specify the initial load of the corresponding buffers.
6. Clear all other buffers (branches, Robotino!).
7. Start a production or customer order and check that everything works fine.

97
Virtual Commissioning with MES4 Tutorial
4. Configure CIROS model respective to the MES4 configured.

1. Configure the CP System options for each component.

1. MES ID in CIROS should be the same as Resource ID in MES4.

98
Virtual Commissioning with FactoryViews[1]
Import Model from Python Script

• Python script to generate model with configured MES4 resource ID can be generated from Festo Factory View, which is the successor
of Festo MES4 Software.
• The script can be executed in CIROS to configure the CP System setup for virtual commissioning.
• With this option, time to insert the models and to configure the resource IDs is saved.
• However, the carriers are not generated from the code. Thus, they have to be added manually from Festo CP System Model Library.

[1] FactoryViews is the new software bundle for MES and web based services. It contains MES4 v3. 99
Virtual Commissioning with FactoryViews[1]
Guide to import model from python script

1. Create a CIROS model.

2. Select Extras → Python → Execute.
3. Select the python script generated, for example, from Factory View, and click
open.
Note: Last python script can be executed again by selecting Extras → Python →
Execute Again or shortcut key Ctrl+Shift+W.
4. Go to top view or shortcut key A.
5. Open Model Library or shortcut key Ctrl+Shift+M.
6. Insert carriers and delete extra carriers.
7. Snap the remaining carriers in place.
8. The model is ready.

Hint:
• In the python script exported from FactoryViews, the modules are snapped in place and MES
ID of the resources are set.
• To reduce graphic power consumption and avoid crash, close all windows and minimize
Model Window before loading the script.
[1] FactoryViews is the new software bundle for MES and web based services. It contains MES4 v3. 100
Virtual Commissioning with Robotino
• Note: MES4 is not communicating with Robotino(s) directly!
MES4 Fleet Manager
• Communication is carried out via the Fleet Manager.
• MES4 is just sending transportation orders like “Go to position
A, grab a workpiece, move to position B, and release the
workpiece over there” to the Fleet Manager
• Fleet Manager itself selects one of the available Robotino(s)
and sends commands like “dock to position A” to the Robotino
to fulfill the MES4 order.

101
Virtual Commissioning with Robotino
Videos tutorial: 21_ConfigureFleetManagerForCiros.avi

Robotino CP-MR-C

Docking kit CP-MR-DOCK

102
Virtual Commissioning with Robotino
Fleet Manager v3 and above

• Option Fleet Manager used with CIROS must be activated.

103
Virtual Commissioning with Robotino
Simulation with CIROS, MES4 and Fleet Manager

• Start simulation • Stop simulation

1. Start MES4, CIROS, and Fleet Manager in any order, but do 1. Stopping simulation in CIROS.
not start the CIROS simulation yet. 2. Reset the CIROS simulation to t=0s.
2. In Fleet Manager, if the server is not started, start the 3. Fleet manager: Stop the Robotino server via Stop Server.
Robotino server via the Start Server button.
Note: Server must be stopped!
3. Start the CIROS simulation.
4. MES4: Clear all Robotino-related buffers.
4. Fleet manager: Select all available Robotinos and switch
them to Automatic.
5. Place your MES4 orders.

Videos tutorial:
01_StartUpRobotino.mp4
22_SimulationOfRobotino.avi
104
Synchronise CIROS Parts in Storage with MES4 Buffers
• During the initialization phase of a CIROS simulation run,
CIROS will ask for the buffer contents of high-bay warehouses
automatically .
• But, whenever the buffer of a high-bay warehouse has changed
within the MES4 while the CIROS simulation is running, one
must click the MES 4 button in CIROS view window to transmit
these changes to CIROS.

105
Running CIROS and MES4 on Different PCs
CIROS → Settings → Model Options

Address = IP-Address of PC
which MES4 is running.

106
Running CIROS and Fleet Manager on Different PCs
CIROS → Settings → Model Options

Address = IP-Address of PC
which Fleet Manager is running.

107
Terms & Definitions in MES4
Customers, orders, order number & order position

• MES4 maintains a list of registered customers which are

allowed to place customer orders.
• Each order has a unique order number (ONo) and may consist
of a couple of different products and parts to be produced.
• Each production part within an order has its own order position
(OPos), ranging from 1 up to the total number of parts of a
particular order.
• (ONo, OPos) is a unique representation of an individual part.

Picture source: MES4 v2 or lower

108
Terms & Definitions in MES4
Operations and parameters

• Operations define the functionality of a production step and are

executed by resources.
• But, MES4 separates between operations and resources, since
there might be several resources able to perform the same type
of operation, i.e., operations are not sub-objects of resources Picture source: MES4 v2 or lower

but allocated to them.

• Vice versa, some resources can execute more than just one
operation.
• Each operation has its own unique ID (OpNo) and might have
no, one or even quite several parameters to adjust the
production step.

Picture source: MES4 v2 or lower

109
MES4 Communication Interface
Cyclic status message Service requests

• The resources send a status update to MES4 in every second. • Resources or other applications query data from MES4 or write
data to MES4.

Resource Resource
Port Port
2000 2001

SPS MES4 SPS MES4

110
Terminology in MES4 Messages
Term Meaning
BoxID Box ID
BoxPNo Box part number
BoxPos Position in box
BufNo Buffer number
BufPos Buffer position
ONo Order number
OPos Order position
Op Operation
OpEnd Operation end
OpNo Operation number

111
MES4 Service Requests
• MES4 offers many services that are required for the operation
of a plant.
• None of the plants use all services, but all services are
available at any time and can be called not only by PLCs but
also by other business applications via a TCP/IP connection. In
addition, a skilled operator can implement additional services,
if they can be mapped to an SQL query of theMES4 database.
Request
• Service calls always follow the request response paradigm, i.e.,
a client sends a call and MES4 response back. Client
Response
MES4
• Internal controller of CIROS model is the virtual representation
of PLC. Thus, it communicates the same way as a real PLC.

112
MES4 Service Requests
Message classification Example:

• Services are uniquely identified by two characteristics:

MClass MNo Name
• MClass (service class)
• MNo (service number) 100 6 GetOpForONoOPos
• The MNo is only unique within an MClass. This means that the service 100 33 GetStepDescription
with MClass 100, MNo 6 is different from MClass 150, MNo 6.
101 20 OpEnd
• They also have a name, but this is of no relevance to the client or to
MES4. It is only used for recognition by humans. 150 5 GetBufPos
• All the messages available can be seen in MES4
• Tools → Com. Simulator
• The messages can be edited
• MES4 → Tools → Config SQL
• Note: Only Administrator can access Config SQL
• Administrator’s password is SolutionCenter

113
MES4 Service Requests
Classes

• Service classes on the right are frequently used. For user MClass Description
defined services, any other classes can be used.
100 Get information from orders and work plans

101 Write information to orders and work plans

110 Request topology related data

150 Request buffers and utilities (incl. boxes) status

151 Write buffers and utilities (incl. boxes) status

200 Request logistic and Robotino information

201 Write logistic and Robotino information

114
MES4 Service Requests
Message packet overview

Request Response

Header Header
• Defined in HeaderGet.xml • Defined in HeaderSend.xml

Standard input parameters Standard output parameters

• Defined in HeaderGet.xml • Defined in HeaderSend.xml

Service specific parameters Service specific parameters

• Defined in MES4 DB • Defined in MES4 DB

115
MES4 Service Requests
Data coding

• MES4 allows two different encoding procedures for service requests and responses.
• The first three or four bytes of each packet are TCP Ident header, which indicates which method the packet uses.

• Binary coding
• Binary coding is primarily used for communication with PLCs on which it is fundamentally easier to handle fixed-address binary data than strings.
• In the binary procedure, a distinction is still made between the Siemens format and the CODESYS format. MES4 also responds to each binary-coded
request in the binary procedure of the same format.

• String coding
• Well suited for implementation in high-level languages or for manual tests. Parameter names and values are transmitted in human-readable form.
• The string procedure also has two forms.
• The complete format can be used for both calls and responses.
• The abbreviated format is only used in MES4 responses if this was requested in the call. was requested.
116
Festo MES4 Interface
• The communication between the MES4 and the CIROS model
requires an object of type MES in the CIROS model.

• A corresponding object named MES Controller can be found in

the CIROS model library Festo MES.
• The MES object from the model library already has all required
communication inputs and outputs. Those inputs and outputs
shall are only be used for external communication and should
not be connected to other inputs or outputs in CIROS.

117
Festo MES4 Interface
• The communication with the MES object inside CIROS is exclusively done via IRL functions. These functions are provided by a
program named MES_commands.irl which is automatically added to a Programs subfolder of your model folder when you add the
MES object. The required functions can be made accessible in your own IRL program by stating FROM MES_commands IMPORT ALL;
• By default, the MES4 interface uses field definitions from the HeaderSend.xml file in the CIROS root directory. If you need own field
definitions, these can be configured in the model options. After configuring field definitions, go to the MES property page of the MES
object and press the Create compatible IO button to create the required object inputs and outputs.

individual ID of the MES object

big / little endian

log the communication messages to the messages window

creates the required inputs and outputs based on the configured field definition file

118
Use Case: Update Resource Status with MES Controller
• At the end of this tutorial, user is able to update to MES4 that the resource is in Automatic, MES mode when simulation starts.

1. Create a CIROS project.

2. In Model Libraries, insert following:
1. Festo MES \ MES controller.
2. Controllers \ Simulation controller
3. Open Project Management window.
1. Create a new project in Industrial Robot Language (IRL) in location <project folder>\Programs. Name it ResourceState.prjx.
2. Assign the project to controller MES_Controller.
3. Add MES_commands.irl in the project.
4. Create a new program. Name it ResourceState.irl. Make it main program.
5. Program ResourceState.irl as in next page.
6. Save and compile the program.
7. Save the project.
8. Run simulation and observe in MES4 Production Control \ Resources.

119
Use Case: Update Resource Status with MES Controller
ResourceState.irl

PROGRAM ResourceState;

FROM MES_commands IMPORT ALL;

BEGIN
{Initiate MES status}
setStateMESMode(true);
setStateAuto(true);
setStateReset(false);
setStateError(-1);

ENDPROGRAM

120
Use Case: Update Resource Status with MES Controller
Steps in screenshots
3 5 8
1

7 9
4
2

121
Use Case: Update Resource Status with MES Controller
Steps in screenshots

10 11 12

13

122
Message Request from CP System to MES4
• CIROS behaves the same as PLC in terms of MES4
communication. Thus a bit coding is used.
• The messages are written in IRL format and can be found in
Project Management.
1. In toolbar, open Programming \ Project Management.
2. In Project Management window, if not yet exist, add following
project.
• <project folder\CF\CPSystems\CPSystem_Allgemein.prjx>
3. Open Projects \ CPSystem_Allgemein(IRL) \ Files.

123
MES Communication Flow Chart
Example: CP-L-CONVEYOR

SPS_A main program Start communications MES_Com.irl

• CPSystem_Allgemein.irl •GetOpForONoOPos • Function callApp
•OpStart

Lab conveyor ID MES_Com.irl Applications.irl

•CIROS_Serie_ID at AI97 = 1 •Function • Function App
•CIROS_GM_ID at AI98 = 0 checkForWorkInThisStation •start the corresponding
•CIROS_App_ID at AI99 = 0 •If Resource ID = 0, standard app
mode
•If Resource ID > =, MES mode

CPLab.irl Function OpEnd

• Function CPLab CPLab_Linearmodul • Write info of next
•Wait for E-stop • Start the belt operation
• Wait RFIDInventory = 1

124
Message Request from CIROS to Fleet Manager
• Like PLC, CIROS Robotino model is the virtual representation of real Robotino. Thus it communicates with Fleet Manager the same
way as a real Robotino.
• The communication messages are written in IRL format and can be found in CIROS → Programming → Project Management →
Projects →RFM_MR.

• Note: RFM = Robot Fleet Manager, MR = Mobile Robot

125
Virtual Commissioning with Soft PLC
Basic knowledge in PLC programming and TIA Portal is required.
Scenario Overview

• Program your PLC against a virtual mechatronic model

• No risk to your hardware if students make mistakes in program code
• Program modules that you don‘t physically own or let dozens of students program the same module even if you only own it once

127
Scenario Overview
All on single PC Software on different PCs

128
Process Summary

1. Prepare a CIROS model with the hardware you want to program

2. Create your hardware configuration and I/O tags in TIA Portal
3. Create a PLCSIM Advanced instance and download the hardware configuration
4. Configure the interface between CIROS and your instance
5. Start programming!

Important:
• CIROS v7.1 is only compatible with Siemens PLCSIM Advanced v3.0 or above!
• CIROS v7.0 or below is only compatible with Siemens PLCSIM Advanced v2.0 or below.

129
Preparing a CIROS Model

• Two approaches are possible:

1. Create a model from scratch

• Maximum flexibility
• Program any CP station you like

2. Load a premade model from the model library

• Get started quickly with minimum effort
• Limited selection of CP systems available

130
Preparing a CIROS Model

Your model usually needs three basic elements to serve for virtual
commissioning with PLCSIM Advanced:

• The mechatronic system you want to program

• A source and sink to generate and remove carriers with parts

• A SimController so CIROS is able to simulate your model

131
Exercise
Preparing a CIROS model from scratch

1. Create a new empty model.

2. Add your mechatronic system from the model library.
For this exercise, add a CP-L-CONV.
3. Add a source and sink from the model library that matches your system.
For this exercise, add a CP Lab source and sink.
4. Connect the source and sink to your CP Lab module.
5. Switch the PLC in your CP Lab module (it’s named SPS_A) to PLCSIM Advanced mode.

132
Starting a PLCSIM Instance

Feel free to choose any PLCSIM Advanced settings that work for you.
The only setting relevant to CIROS is the instance name. Choose one
you like and remember it. You’ll need it later.

Some recommendations:
• For Online Access, choose PLCSIM unless your simulated PLC
needs to communicate over the network. This mode makes the
connection to TIA Portal effortless
• Leave Time Scaling off. CIROS has its own time scale and will
make sure the PLC keeps track if you speed up the simulation
beyond real-time
• Choose ET 200SP for PLC type as that matches the physical PLC in
most CP hardware systems

133
Creating the Hardware Configuration and IO Tags in TIA Portal
Hardware configuration IO tags

You can configure your PLC in any way you like. You can freely name your inputs and outputs, as long as the
Ideally, it should have at least the number of digital and analog address and the type of an input/output is correct.
I/Os that the physical PLC inside your chosen CP system has. If you like you can skip the inputs and outputs that are not
connected to anything in your CP system.
Refer to the Festo Didactic Infoportal (https://ip.festo-
didactic.com) for an I/O listing of your CP system. Alternatively,
find the relevant information in your manual or circuit diagram.

134
Exercise
Creating the hardware configuration

Detailed instructions how to do the hardware configuration in TIA Portal are beyond the scope of this document. Refer to the
courseware ‘Device configuration’ if you’re having trouble.

For this exercise, we’re configuring the PLC as we would a real CP-L-CONV module with a Siemens IO-Link 1.1 conformant RFID device.

1. Create a new TIA project

2. Add a S7-1512SP F-1 PN PLC to your project (6ES7 512-1SK01-0AB0)
3. Add two DI 8x24VDC HF (6ES7 131-6BF00-0CA0)
4. Add two DQ 8x24VDC/0.5A HF (6ES7 132-6BF00-0CA0)
5. Add a CM 4xIO-Link (6ES7 137-6BD00-0BA0)
6. Add a server module (6ES7 193-6PA00-0AA0)
7. Set the IO-Link master’s input/output type to 64/64 and shift the starting I/O addresses to address 10

135
Exercise
Creating the hardware configuration

136
Exercise
Setting up the I/O tags

1. Find the list of I/O addresses for the CP-L-CONV at https://ip.festo-

didactic.com/InfoPortal/CPFactoryLab/hardware/base/datasheet.php?model=CP-L-CONV&lang=en
2. Create a new tag table
3. Enter all tags listed on the Infoportal into your tag table

Note:
Depending on the revision of a physical CP-L-CONV, any address listed on the Infoportal in byte 18 might require to be shifted to byte
42. This is only relevant if you plan to download this TIA project to a real CP-L-CONV. In CIROS the absolute I/O addresses don’t matter.

137
Exercise
Setting up the I/O tags

Note the addresses

are shifted from
18.x to 42.x.
138
Exercise
Enabling simulation support

1. Open the project properties.

2. On the Protection tab, check Support simulation during block compilation.
3. Compile and download it again. It should work without a problem now

139
Exercise
Downloading project to PLC instance
.1. Compile the project.
2. Download it to your simulated PLC.
If Online Access in PLCSIM Advanced is set to PLCSIM mode, this is
almost fully automatic.

140
Configuring the Interface

The virtual PLC in CIROS has a large number of inputs and outputs, most of which are unused or used for internal processes inside
CIROS. A few virtual I/Os correspond to the I/Os of the PLC inside a real CP system, though. These are named DIN0_x0 to DIN18_x7
and DOUT0_x0 to DOUT18_x7, after the absolute addresses of the real PLC’s I/Os.

Name of a virtual I/O,

CP system you want to program corresponding to %I0.0 in the real
CP module.
Virtual PLC inside module
I/O address inside CIROS.
Completely irrelevant to your TIA project.

Current value of a virtual I/O. For inputs

these come from simulated sensors. For
Virtual inputs and outputs outputs, they control a simulated
actuator.

141
Configuring the Interface

You can connect each virtual PLC in your CIROS model to exactly one PLCSIM Advanced instance.
You have to configure our CIROS PLC to connect to the right instance and to hook up the virtual CIROS I/Os to the correct TIA I/Os.

142
Exercise
Configuring the interface

Configure your CP-L-CONV model to connect to your instance.

All of this is done in CIROS. TIA doesn’t know anything about the CIROS interface.

1. Open the properties of your virtual PLC (SPS_A)

2. On the PLCSIM Advanced page, select Find instance by name.
3. Enter the name of your PLCSIM Advanced instance

143
Exercise
Configuring the interface

1. Go to the subpage Items

2. Click on Connect
3. Open either the entry that says all or HMI visible,
depending on your preference. The latter only offers
you I/O tags that have been declared as Visible in
HMI engineering inside TIA
4. Under this entry, open I/O

Note that you’re also offered Memory, Counters and

Timers and Data blocks. You can hook up CIROS I/Os
to any of these but in this exercise, we’ll only use I/Os.

144
Exercise
Configuring the interface

Virtual I/Os of the CIROS PLC

I/O tags configured in TIA

145
Exercise
Configuring the interface

1. From the list of I/O tags on the right, drag and drop
each I/O to the matching entry on the left.
Note: Connect CIROS inputs with PLC inputs, and CIROS
outputs with PLC outputs.
2. When done, click “Apply”.
3. Optionally, click “Connect” again to disconnect.

Drag and
drop
Hint: You can select multiple I/Os from the right if they
are in the right order and drag them to the left at once.

146
Exercise
Run the simulation

1. Click the play button to start the simulation

2. Use TIA to go online / connect to your PLC instance

147
Exercise
Run the simulation

1. In TIA, open your tag list and monitor it

2. Test the connection by clicking on the virtual green start button inside CIROS. You should see the value of %I1.0 change in TIA

148
More Information
Mapping CIROS I/Os to PLCSIM Advanced instance I/Os

Inputs Inputs

Outputs Outputs
More Information
Mapping CIROS I/Os to real PLC via EasyPort and EzOPC

Software Hardware

OPC DA USB Syslink

Inputs Inputs Inputs Inputs

Outputs Outputs Outputs Outputs

150
Common Issues
Can’t download project to PLC instance anymore

Once CIROS has established a link to a PLCSIM instance, that instance is bound to the simulation. Only when the CIROS simulation is
running, will the instance run as well.

Should TIA appear to be stuck when downloading to the instance that is likely because your CIROS simulation is paused. As soon as
you start the simulation, the download will continue.

151
Remote Connection between CIROS and PLCSIM Advanced

If you’re running CIROS and PLCSIM Advanced on different machines, you need a little bit of
extra configuration.

1. PLCSIM Advanced must use the Virtual Ethernet Adapter

2. The communication interface must be set to the network interface through which you’re
connecting to CIROS
3. The runtime manager port must be enabled. Note the port number written here

152
Remote Connection between CIROS and PLCSIM Advanced

You also have to let CIROS know, where to find PLCSIM Advanced.

1. Go to the virtual PLC’s properties

2. Open the PLCSIM Advanced page
3. Check Activate remote connection
4. Enter the IP address of the PC where PLCSIM Advanced is
running
5. Enter the runtime manager port number that is configured in
PLCSIM Advanced

153
Simulation
Simulation Kernel
• Settings → Model options allows for configuring the way in
which the simulation status will be updated during simulation. 2

• Mainly characterized by two parameters,

• model computation
• relationship model time / real time

155
Simulation Kernel
Model computation

• Simulation increment specifies the intervals in which the

simulation status and its visualization will be updated.
• Default of 0.04s means 25 updates per second of model time.
• Provided that the computer CIROS is running on is powerful
enough, this results in real-time behavior!
• Increasing the Simulation increment leads to fewer calculations
of simulation states which might lead to some strange
behavior.

Rule of thumb: Do not touch the default value for the simulation
increment!

156
Simulation Kernel
Relationship model time / real time (1)

• Progress preferably in real time

• Progress of model time is restricted to real time.
• Default option, ensuring that a CIROS model behaves like a similar
real CP Lab / Factory system (wrt. process times).
• Allow the skipping of model visualizations
• By default, the visualization gets updated with every simulation
increment.
• Skipping some of these calculations might give CIROS the chance to
keep track with real time.
• Allow the skipping of waiting times
• To keep track with real time, one can also skip simulation updates
when nothing has changed.

157
Simulation Kernel
Relationship model time / real time (2)

• Progress faster than real time (if possible)

• Allows CIROS to simulate as fast as the underlying hardware
environment allows.
• Skipping some visualizations results in even faster computations.
• The speed can be set to adjust how fast the simulation should be in
Model visualization after __ simulation increments …
• For example, to simulate 5x faster than real time, configure it as
follow: Model visualization after 5 simulation increments …

158
Simulation Kernel
Relationship model time / real time (3)

• Progress slower than real time

• Mainly for debugging purposes.

159
Simulation Kernel
Remarks

• Timestamps in CIROS are based on model time, while in MES4 timestamps are based on real time!
• Example of what could happen if model time differs from real time.
• Assume that a single step of an MES4 workplan takes 10s of real time on a corresponding real application module.
• If CIROS is keeping track with real time (model time = real time), the step will be simulated in 10s of real time, too.
• If CIROS is running faster, this step still requires 10s of model time, but CIROS can simulate that 10s of model time in (to give an
example) 2s of real time. MES4 will record that the operation required only 2s of real time!
• Therefore, if CIROS is simulating faster/slower than real time the process times the MES4 is measuring are no longer reliable!
• Due to the different ways of measuring time, it is not possible to simulate the annual production of a CP Lab / Factory within a few
hours!

160
Reduce Simulation Computing Requirement
Disabling shadow simulation

• Calculating shadows during simulation allows for a more natural appearance of the model but requires a lot of CPU/GPU
performance. Simulation might slow down significantly!
• For less powerful hardware environments disabling shadows improves overall simulation performance.
• Screen Space Ambient Occlusion (SSAO)
• Shadow light sources

161
Reduce Simulation Computing Requirement
Screen Space Ambient Occlusion (SSAO) (1)

• SSAO is a computer graphics technique for efficiently approximating the ambient occlusion effect, caused by ambient lightning, in
real time.
• While the implementation in principle is quite fast, it nevertheless requires substantial computation power.

without SSAO with SSAO

162
Reduce Simulation Computing Requirement
Screen Space Ambient Occlusion (SSAO) of a model (2)

• Use Model Explorer → Model → Lightning → Ambient light → Properties to disable or enable Screen Space Ambient Occlusion.

163
Reduce Simulation Computing Requirement
Shadow light source 1

• Usually, light source 1 is causing shadows, while light sources 2 to 7 and headlight do not have that option
• If enabled the simulation of that shadow depends on the position of light source 1 and its properties

Position & direction of

light source 1

without shadows caused by light source 1 including shadows

164
Reduce Simulation Computing Requirement
Shadow light source 1 of a model

• Use Model Explorer → Model → Lightning → Light source 1 → Properties to disable or enable shadow simulation.

165
Reduce Simulation Computing Requirement
SSAO and shadow source of CIROS application.

• Disabling shadows like shown on the slides before is valid for a

particular model only!
• To disable or enable shadows regardless of the model use
File → Application options → Display.

166
 1

Code Sequence Trace

• Simulation is controlled by the chosen controller in the project and its code, whether
PLC controller or robot program, can be traced during the simulation.

1. The function can be activated in Programming → Project Management.

2. To enable or disable tracing of a particular controller, check the option Code
sequence trace for the controller.
3. To enable or disable tracing of all controllers in the project, right click on Controllers
and choose the option.
2

167
Visualising Sensor Data
• Depending on the model options, measured range and values
are not visualized by default in view window.

• Displaying sensors can be achieved by configuring Settings →

Model options → Display → Sensors

• Measured value depends on the sensor type

Light barrier Obstacle detected

Distance sensor Distance to obstacle

Colour sensor Colour

168
Visualising Sensor Data
• In rare cases one must enable the visualization of sensor data
by modifying the properties of each individual sensor.

Sensor visualisation off Sensor visualisation on

169
Data Logging
• Data logging in CIROS allows for storing and visualization of values of inputs, outputs, variables, etc. during simulation.
• Example shown here: Visualization of the time needed for performing a status update.
• Configuration of data logging is available at Settings → Model options → Logging.

170
Data Logging
Simulation speed restricted to real time

Almost all the 40ms the

simulation is waiting to
avoid being faster than
real time.

Time required for

updating the simulation
status is almost zero in
this setup.
171
Data Logging
Simulation speed as fast as possible without manual working place

Time required for

updating the
simulation status.

without both, SSAH

without SSAO
and light source 1
shadows
shadows

172
 2

Data Logging
Create new profile

• Apart from default data logging profiles, it is possible to log own data to simulate
the model built.
• To log own data, a logging profile containing desired data must be created, it can be
1
created in Settings → Model Options → Logging → Profiles.

1. In section Profile, select New…

2. Give a Name.
3. Use the filter option to filter the selection.
• Possible data are robot positions, joint coordinates and IOs of the objects. 4

4. Use the arrow buttons to select and deselect data.

5. Finally, click Apply to create the profile.

• Profile created can then be added to logging window in Settings → Model Options →
Logging, section General. 5

173
Simulation Control in CP System
Industrial Robotic Language (IRL) Python

• Located in <project file>\CF\CPSystems. • Located in <project file>\CF\py.

• Scripts can be opened in CIROS in project management • Translate MES4 part number to CIROS part number.
window. • Replicates workpieces and boxes.
• Programming → Project management
• Send string requests to MES4
• Main simulation controller.
• Communicates with MES4 and Fleet Manager.
• Control the model movements.
• Read input values and write the output values.

• Note: RFID data structure in CIROS is different from in real

system.
174
CP System Simulation Controller

A project contains different controller scripts.

Main program is called cyclically and
sub programs are called in main program.

A project is assigned
to the controller.

Project information.

175
Python
Python in Model Libraries
• Python 3.7 or higher is required for the support of CP Lab / Factory model library.
• Replication of CP Lab / Factory workpieces within CIROS is based on various Python scripts, compared to previous versions this
change within the CIROS kernel simplifies the integration of user defined workpieces.

• If not already installed, CIROS installation wizard will install Python and add it to Windows path during the setup in silence mode.

• In case Python in removed…

• Due to various reasons, like uninstallation of other applications in the same PC, Python can be uninstalled or removed from
Windows path.
• In this case, CIROS will throw an error, most commonly cirospluginpython.dll not loaded.
• When this happens, user should check whether the correct Python version is installed and is it in the Windows path.

177
Python in Model Libraries
Adding python to Windows path (1)

• To define Python in System Environment Variable Path in Windows 10: 2. Open Environment Variables.
1. Open System Properties. Advanced → Environment Variables

Menu → Settings → System → About → Advanced System Settings

178
Python in Model Libraries
Adding python to Windows path (2)

3. Edit Variable Path in System Variables. 4. Insert the path to Python and Python Scripts folder here.
System Variables → Path → Edit For example: C:\Program Files \Python 38\ and C:\Program Files \Python
38\Scripts\

5. Restart the computer.

179
Python Installed but Not Working
• When different python versions are installed in the same
computer, CIROS always selects the version on top of the
Windows environment path list.
• When the version on top of the list is not supported by CIROS,
there will be an error.
• Typical error message is “cirosPluginPython.dll not loaded”.

• Steps to solve this problem

1. Open Windows Environment Variable.
2. Edit System variables.
3. Move the python with correct version up to the top.

180
Python Scripts
• CIROS v7 and above works with Python scripts. The scripts can be called for following purposes
• Creation and modification of model.
• Controller for simulation or components.
• Define user defined commands in context menu.

• There is an integrated python module for CIROS, “Ciros”

• Overview of the functions in the module can be called from Menu → Extras → Python → Show function list
• In CIROS 7.1, there are currently 19 classes and 275 commands
• Example models can be found in C:\Program Files\Festo Didactic\CIROS 7.0\CIROS Studio\Example Models\Help\Python

• Requirements
• Python 3 is installed
• Supported versions are 3.6, 3.7, 3.8 and 3.9
• The used version will be chosen automatically
• First line in python function list states the version used.

Note:
• Python must be defined in windows PATH-variable.
• The script cannot contain endless loop.
181
Python Scripts
Python scripts can be executed by following methods 1

1. Manually
• Application script (Concurrent or blocking)
• With or without simulation 2
• Menu Extras → Python → Execute

2. By a trigger during simulation

• Simulation script (Blocking) 2
• Parameters
• Element: Specify the element that calls the script.
• Trigger: Specify event that trigger the call.
• File: The script to be called.
• Function call: Function in the script to be called. Optional.
• Output: Defines whether outputs should be written in message window or not.

3. Python controller
• Controller script (Concurrent) 3

• A controller object, e.g. simulation controller is required.

182
Python Scripts
Execution type Call type

1. Concurrent 1. Simulation script

• The python script is executed while CIROS is running. • Invoked by a trigger during simulation.
• This execution type is required for scripts containing GUI elements. • The execution type is 'blocking'.
2. Blocking 2. Controller script
• First, CIROS is interrupted. Then, the python script is executed up to • Invoked upon simulation start. Acts as a controller for a specific
its end. Finally, CIROS is resumed. object.
• This execution type is required for scripts containing special • The execution type is 'concurrent'.
commands e.g. 'muteGUI'.
3. Application script
• Invoked by a menu command or a command line argument. The
execution type can be chosen by the user.
• Please use #CIROS pragma: blocking or #CIROS pragma: concurrent
in the first line of your script.

183
Built-In Function List
1. Show the function list by clicking Menu → Extras → Python → Show function list.
2. Copy the function list and paste it in an editor, for example ‘Notepad++’.

184
CP System Construction Helper
• A python library contains of four classes.
Class Explanation

CPFactoryConstructionHelper Constructs a single line of CP-Factory base modules from left to right.

CPLabConstructionHelper Constructs a single island of CP-Lab modules from left to right, base modules and corners must be added in
the correct order, build order is from left to right.

CPRobotinoConstructionHelper Construct Robotino and related modules

CPSystemConfigurationHelper This can be used to change the configuration of certain modules. Please note that u need to give the correct
object name as it appears in the model, for example CP-L-BRANCH_1 for the second added branch module.

• Note: This library does not come in default with the installation. It might be found in the CIROS project configured by Festo Didactic
in folder python. If it is not found, please contact us to request for it.

185
Use Case: Common TCP/IP Communication
Tutorial: Send robot TCP to a TCP/IP server.

• At the end of this tutorial, user is able to get a robot TCP in joint coordinate and send it to an external TCP/IP server using common
TCP/IP communication protocol with a python script.
• The example will be demonstrated with a CP-F-RASS_Mitsubishi modell.

186
Use Case: Common TCP/IP Communication
1. Insert CP-F-RASS_Mitsubishi model in CIROS.
2. Create a python script named TcpIpClient.py.
3. Program the script as shown in next page.
4. Start a TCP/IP server.
Example: With open source software ‘Hercules’.
5. In CIROS, select Extra \ Python \ Execute.
6. Select the python script.
7. Cartesian coordinate is received in the server.
8. Send a reply to close the connection.

187
Use Case: Common TCP/IP Communication
Python script

#CIROS pragma: concurrent def robotTCP():

rass = ciros.Object('Montage_RV-4FL') #Find the object
import Ciros2 as ciros flange = rass.getGripperpoint('Flange') #Find the gripper
import CirosUtil coord = flange.getFrame(origin='OBJECT').getTranslation() #Get translation
import socket coordinate of gripper / TCP of robot
return str(coord)
def TcpIpClient(msg):
HOST = "127.0.0.1" TcpIpClient(robotTCP())
PORT = 9000
with socket.socket(socket.AF_INET, socket.SOCK_STREAM) as s:
s.connect((HOST, PORT))
s.sendall(msg.encode('utf-8'))
data = s.recv(1024)
print(f"Received {data!r}")

188
OPC UA Interface
CIROS as OPC UA Client
1. Change controller object type to OPC UA client. 1.1

1. Select the object in Model Explorer.

2. In Properties window, select General → Object type.
3. First, change object type to inactive object to clear filter.
1.2
4. Then, all the available object types will be shown, select OPC UA
client.
1.2
2. Change controller control to Simulation controller. 2

1.4

1.3

190
 3

CIROS as OPC UA Client

1. In Properties → OPC-UA-Client, search for the endpoint of OPC UA
server.
1. If endpoint did not change, you can type the URL directly in the field.
2. Expand OPC-UA-Client and select Items.
3. Click on Connect. 2

4
4. Assign the OPC UA nodes in server to the internal IOs.
5. Select Apply.

5
1
1.1

191
Robot Programming
Mitsubishi
Mitsubishi Industrial Robot
Electric RV-4FL robotic arm
Wrist
J5-axis joint
Type Articulated robot
J4-axis
Number of axes 6 Lower arm
Gripper flange
Ultimate load 4 kg Elbow
J6-axis block
Maximum reach radius 649 mm J3-axis

Movement range 480° / 240° / 164° / 400° / 240° / 720° Upper

arm
Maximum composite speed 9048 mm/s
J2-axis
Cycle time 0.36 s
Position repeatability ± 0.02 mm
Weight 41 kg J1-axis

Tool wiring 8 I/O Base

Protection rating IP67

193
Mitsubishi Industrial Robot
Robot controller CR750-D

Programming language MELFA-BASIC-V

Number of programs 512
Positions / program 3900
Programming Teach box / PC
Power supply Single-phase 180 – 253 V AC
Interface RS422 / ethernet / USB / digital
I/O
Dimensions (H x W x D) 430 mm x 425 mm x 174 mm
Weight 16 kg
Protection rating Ground position / IP20

194
Mitsubishi Industrial Robot
Teach box R56TB

Menu navigation German, English, French, Italian

(language)
Features Operating, programming and monitoring all robot features
Programming and Reading out information even during the running system;
Monitoring Programming using a virtual keyboard;
Display of up to 14 lines of programming code;
I/O Monitoring of up to 256 inputs and 256 outputs;
Maintenance display of service intervals;
Trouble indication of the last 128 alarms
Display Touchscreen with background lighting 6,5" TFT display
(640 x 480 pixel), 65536 colours
Interface USB, combined RS422 and ethernet interface
Connection Direct connection to the robot controller, cable length 7m
Protection rating IP65
Weight 1,25 kg

195
Layout and Windows

Programme window

Model window

Position list window

196
CP-F-RASS
Robot simulation

• RASS stands for Robot ASsembly Station.

• It is possible to simulate the Mitsubishi robot program in CIROS
environment.
• The robot program requires several input parameters, which usually
comes from MES4 or PLC. For standalone robot simulation in CIROS, user
has to provide the input parameters manually.
• Following are the input parameters are required for standalone CIROS
robot simulation:
1. Program number.
• Program 1 : Assemble PCB
• Program 2 : Assemble PCB and front fuse
• Program 3 : Assemble PCB and rear fuse
• Program 4 : Assemble PCB and both fuses
2. Position in box.
197
CP-F-RASS
General information

• Attention: General knowledge of Mitsubishi robot and robot programming are required to proceed in this chapter. Please be
informed about Mitsubishi robot program structure, programming language, and I/O connections before proceeding.
• The robot programs are written in Melfa Basic V (MBA5) with extension .mb5, which is the programming language of Mitsubishi
robot.
• Positions are stored in the position list with extension .pos.
• There is a robot project in CP-F-RASS model, which have the same programs as in actual robot. However, the I/O channels and tool
changing mechanism are modified to suit the modelling environment.
• In CIROS simulation, a main program RobotSystemDriver.mb5 is used to simulate the slot allocation in actual robot controller.
• Generally, a program name can be any string characters. However, PLC only calls the program by integers. To allow the new program
to be able to function in real robot, the program name should be numbers.

198
CP-F-RASS GRPVACOFF.mb5

GRPVACON.mb5
Switch off vacuum gripper

Switch on vacuum gripper

INITIALIZE.mb5 Initialize input and output variables

Programs list MONITORHOME.mb5 Check if robot arm is at home position

MONITORPALWS.mb5 Check if robot arm is at PCB box position

RobotSystemDriver.mb5 Main program. Assign subprograms to slot.
MOUNTBOTFUSE.mb5 Mount rear fuse
999.mb5 Reset robot
MOUNTPCB.mb5 Mount PCB to front cover
1.mb5 Assemble PCB to front cover
MOUNTTOPFUSE.mb5 Mount front fuse
2.mb5 Assemble PCB and front fuse to front cover
MOVHOME.mb5 Move robot arm to home position
3.mb5 Assemble PCB and rear fuse to front cover
PCBTRAYCNTRL.mb5 Check PCB box lock signal and PCB position count
4.mb5 Assemble PCB and both fuses to front cover
PICKFRMSTOPR.mb5 Pick workpiece from stopper
5.mb5 Demo program. Assemble and disassemble PCB in front cover.
PICKFRMVISION.mb5 Pick workpiece from vision field
123.mb5 Check all positions in PCB box. Assemble and disassemble all PCBs in box.
PICKFUSFRMAG.mb5 Pick a fuse from fuse magazine
234.mb5 Camera test program. Pick front cover from stopper, place to vision field and run camera. Repeat
PICKNEWTOOL.mb5 Pick a new gripper
four times.
PICKPCBFRPAL.mb5 Pick PCB from PCB box
255.mb5 Calculate positions in box based on four positions taught
PICKWPFROMASS.mb5 Pick workpiece from assembly position
ENERGSAVEVACU.mb5 Switch on vacuum gripper when workpiece is loose
PLACETOSTOPR.mb5 Place workpiece to stopper.
GETCAMRESULT.mb5 Get camera result
PLACETOVISION.mb5 Pick workpiece from stopper to vision field
GETCURTOOLNO.mb5 Get current tool number
SENSORCHECK.mb5 Check sensors at stopper, assembly position, fuse magazines and input parameter for PCB position
GETFUSEMAGNO.mb5 Get fuse magazine number
in box.
GRPCLOSE.mb5 Close gripper
SENSORCHECK1.mb5 Check sensors at stopper, assembly position and input parameter for PCB position in box.
GRPLOCK.mb5 Lock the gripper to robot arm flange
SENSORCHECK6.mb5 Check sensors at stopper position
GRPOPEN.mb5 Open gripper
UBP.mb5 User base program. Global program contains all global variable, flags and positions.
GRPRELEASE.mb5 Release gripper from robot arm flange

199
CP-F-RASS
Controllers and I/Os Montage_RV-4FL Index Type SPS_Roboter Index Type Description
I_Stop 100 DI DOUT_100_x0 40 DO Stop robot
program
• Station CP-F-RASS has two controllers,
I_Start 101 DI DOUT_100_x1 41 DO Start a robot
• PLC controller program
IDATA_(0-15) 116 – 16 Bit AOUT_W102 002 AO Program
• Robot controller 131 DI number in
binary
• In CIROS, the station has two controllers as well. DI_PCBPalletNo_(0-7) 172 – 8 Bit AOUT_B109 004 AO Position in
179 DI PCB box
• SPS_Roboter is the virtual representation of PLC controller
HOpen_1 900 DO Open
gripper
• Montage_RV-4FL is the virtual representation of robot
HClose_1 901 DO Close
controller gripper

• The I/Os are linked internally in CIROS model. HOpen_3 904 DO Release
gripper
HClose_3 905 DO Lock gripper

200
CP-F-RASS
Grippers’ tool number

• Each gripper has a tool number. It is important to select the right tool as different TCP is used for different tools.
• Tool 1 : Vacuum gripper.
• Z-offset relative to flange TCP 205 mm.
• C-rotation relative to flange TCP 33.5°.
• Tool 2 : Parallel gripper for front cover.
• Z-offset relative to flange TCP 170 mm.
• C-rotation relative to flange TCP 33.5°.
• Tool 3 : Parallel gripper for fuse.
• Z-offset relative to flange TCP 151.5 mm.
• C-rotation relative to flange TCP 33.5°.
• Tool 4 : No gripper.
• Z-offset relative to flange TCP 0 mm.
• C-rotation relative to flange TCP 0°.

201
CP-F-RASS
List of default positions in CIROS environment for reference
14 15 16
No Definition Position

1 P_AssemblePCB (-140.03,-367.01,109.01,-179.73,0.09,89.95)(7,0)
11 12 13
2 P_PCBPalletOrigin (93.00,276.00,213.00,-180.00,0.00,90.00)(7,0)

3 P_PCBPaletXDir (-140.10,276.00,213.00,-180.00,0.00,90.00)(7,0)

4 P_PCBPaletYDir (93.00,398.00,213.00,-180.00,0.00,90.00)(7,0) 3 5

5 P_PCBPaletXYDir (-140.10,398.00,213.00,-180.00,0.00,90.00)(7,0)
9 10
6 P_CarrierStop1 (402.50,-267.00,171.50,179.73,-0.09,90.05)(7,0) 1 7
8 2 4
7 P_Vision (30.00,-350.00,101.50,180.00,-0.00,90.00)(7,0)

8 P_AssembleWp (-139.00,-362.00,114.00,-180.00,-0.00,90.00)(7,0)

9 P_AssembleFuse1 (-138.97,-401.18,127.13,-180.00,0.00,180.00)(7,0)

10 P_AssembleFuse2 (-138.97,-388.18,127.13,180.00,-0.00,180.00)(7,0)
6
11 P_FuseMagazine1 (-300.65,-430.30,160.30,177.86,-42.56,-177.96)(7,0)

12 P_FuseMagazine2 (-299.24,-360.21,159.46,177.87,-42.57,-177.96)(7,0)

13 P_FuseMagazine3 (-299.44,-290.40,159.99,177.87,-42.57,-177.96)(7,0)

14 P_GrpStorageVac (-395.65,-125.00,484.90,-180.00,-0.00,-0.00)(7,1)

15 P_GrpStorageWp (-395.65,0.00,484.90,-180.00,0.00,0.00)(7,1)

16 P_GrpStorageFuse (-395.65,125.00,484.90,-180.00,-0.00,-0.00)(7,0)

202
Steps to configure CP-F-RASS for simulation
1. Create a new CIROS project. 5. Assign required I/Os to IO monitor.
1. Open an I/O monitor window, it can be any I/O monitor.
2. Insert and snap following from CP System model libraries.
2. Drag the Outputs from Model Explorer to I/O monitor window.
1. CP-F-RASS (Mitsubishi)
3. Required Outputs are in Objects → CP-F-RASS_Mitsubishi → SPS_Roboter
2. CP-F-SOURCE
→ Outputs
3. CP-F-SINK
1. AOUT_W102 (analogue 002) : robot program
3. Optional: Hide safety glass. 2. AOUT_B109 (analogue 004) : position in PCB box
1. In Model Explorer, choose Objects → CP-F-RASS_Mitsubishi → Geometrie → 6. Change source part number to 210.
Geometrie_Umhausung 1. In Model Explorer, select CP-F-SOURCE.
2. In Properties, select Visualization. 2. In Properties → CP System, change Part Number to 210.
3. Click Invisible.
4. Open robot program in project management.
1. In Project Management, right click on Projects and select Open.
2. Select <project folder>\CF\Rob_Montage\RV-4FL\Montage_RV_4FL.prjx. Note: The configured model can be saved as a template which can be
3. In Project Management, select Controllers → Montage_RV_4FL
opened with CIROS Studio and Education in robot programming lessons.
4. Assign project Montage_RV_4FL to the controller.

Video tutorial: 51_ConfigureRASSForRobotProgramSimulation.mp4

203
Steps to simulate CP-F-RASS
1. Optional: To reduce computing power, close all windows except model window and I/O monitor, e.g. Model Explorer, Properties,
Project Management, etc.
2. Start simulation.
3. Give a robot program and position in box in I/O monitor and activate override.
1. For example: robot program 1 and box position 3.
• AOUT_W102 = robot program → Value = 1
• AOUT_B109 = position in box → Value = 3

5. Press on green source button in model window.

6. Observe the program.
• To run another robot program, repeat step 3 to 6.
• To restart simulation, repeat step 2 to 6.

Video tutorial: 52_SimulateRASSRobotProgram.mp4

204
Simulate Real Robot Program in CP-F-RASS Model

• It is possible to simulate real CP-F-RASS robot program in CIROS.

• However, the program has to be modified to suit the simulation environment, for example, the I/Os address and tool changing
mechanism.
• Besides, the simulated program does not connect to a camera. Thus, the subprogram which connects with camera has to be
commented out.
• The modified robot program can be saved as a template project and be used repeatably in robot programming classes as it is
portable with both CIROS Studio and CIROS Education.

Ready to use project: CP-F-RASS_RobotProgramming_v717

205
Simulate Real Robot Program in CP-F-RASS Model
Steps to modify robot program (1)

1. Create a new CIROS project. 6. Copy following files from <project folder>\CF\Rob_Montage\RV-4FL to
2. Load and snap following models in place from CP System model the robot program folder.
1. RobotSystemDriver.mb5
libraries.
2. Montage_RV_4FL.prjx
1. CP-F-RASS (Mitsubishi)
3. ENRGSAVEVACU.mb5, if not exist
2. CP-F-SOURCE
4. MonitorHome.mb5, if not exist
3. CP-F-SINK
5. MonitorPalWS.mb5, if not exist
3. Change Part Number of CP-F-SOURCE to 210. 6. PCBTrayCntrl.mb5, if not exist

4. Place all the real robot programs in a single folder and place the folder 7. In CIROS, open Project Manager, open the copied project
in CIROS project folder. Montage_RV_4FL.prjx in robot program folder and assign it to
controller Montage_RV-4FL.
5. In the folder, delete following files.
1. Files with type .bak. 8. In Project Manager, open Projects → Montage_RV_4FL (MBA5) → Files
2. Files with type .prjx. and delete the files which do not exist.

206
Simulate Real Robot Program in CP-F-RASS Model
Steps to modify robot program (2)

9. In CIROS, change the following in all files in the project. 3. Make following changes.
1. Bits and bytes in I/O definitions 1. Add following lines in 999.mb5.
P_tGripperVac=(0,0,205,0,0,33.50)
From To From To From To
P_tGripperWP=(0,0,170,0,0,33.50)
2032 132 2072 172 2148 248 P_tGripperFuse=(0,0,151.5,0,0,33.50)
P_tGripperNone=(0,0,0,0,0,33.50)
2033 133 2144 244 2150 250
2. Comment out or delete all position declarations in UBP.mb5 and add following lines.
2040 140 2147 247 2151 251
Def Pos P_tGripperVac
2064 164 Def Pos P_tGripperWP
Def Pos P_tGripperFuse
2. Tool changing mechanism Def Pos P_tGripperNone
From To 3. Change following positions to reference positions in UBP.pos. The location of tool
magazine in CIROS model is different from actual robot. Thus, the offsets are too large to
M_Tool = m_GripperFuse Tool P_tGripperFuse
be ignored.
M_Tool = m_GripperNone Tool P_tGripperNone P_GrpStorageVac = (-395.65,-125.00,484.90,-180.00,-0.00,-0.00)(7,1)
P_GrpStorageWp = (-395.65,0.00,484.90,-180.00,0.00,0.00)(7,1)
M_Tool = m_GripperVac Tool P_tGripperVac P_GrpStorageFuse = (-395.65,125.00,484.90,-180.00,-0.00,-0.00)(7,0)
M_Tool = m_GripperWP Tool P_tGripperWP 4. Comment out or remove all lines calling camera related subprograms, for example the
line calling GetCamResult in program 1 to 5.mb5.
HOpen 6 HOpen 3
REM CallP "GetCamResult", CamPrgNumber%
HClose 6 HClose 3
10. Save all and compile the project.
207
CP-F-RASS Robot Programming
Robot programming example ‘gripper test’ (1)

• The program is independent of all the other robot programs, but uses positions in UBP.pos.
• It is written in MBA V and does the following.
1. Move robot arm to home position.
2. Move robot to parallel workpiece gripper magazine.
3. Mount the gripper.
4. Remove gripper from magazine.
5. Open gripper.
6. Close gripper.
7. Store gripper back to magazine.
8. Move robot arm back to home position.

Note: For more programming example, see tutorial video: 50_RASS-Programming.mp4.

208
CP-F-RASS Robot Programming
' TODO add your code here ' Store gripper back to magazine
Robot programming example ‘gripper test’ (2)
MVS P_GrpStorageWP
' Move to home position HOpen 3
1. Create a CIROS project and load CP-F-RASS from CP System model libraries. MOV P_Home
2. Make sure a project is assigned to controller Montage_RV-4FL and UBP.pos is in DLY 1 ' Move back to home position
MVS P_GrpStorageWp, -30
the project.
' Mount parallel workpiece gripper JOVRD 100
3. In Project Management, right click on Projects → <project name> → Files and MOV P_PCBPalletHelp MOV P_PCBPalletHelp
choose new. MOV P_GrpStorageWp, -30 MOV P_Home
JOVRD 50
4. Create a Melfa Basic V program and name it RASS-GripperTest.mb5. MVS P_GrpStorageWp END
5. With the programming window being the active window, select Programming → HClose 3
MVS P_GrpStorageWp + P_ToolX80
Programming assistant.
DLY 1
6. Uncheck Declare inputs and outputs and click OK.
' Open and close gripper
7. In the programming window, add the lines shown in right. HClose 1
8. Save the program. HOpen 1
DLY 1
9. In Project Management, right click on the program and select Set main program. HOpen 1
10. Compile the project. HClose 1
DLY 1
11. Run simulation.

209
Move Robot Manually
• There are several ways to move robot manually in CIROS.

1. Move the robot directly to a position on position list.

• Double click on the position.

2. Double click on any location in model window.

210
Move Robot Manually
3. Move the robot with Teach-In panel.
• Gripper can be controlled in section Gripper output.

211
Mount and Release a Gripper Manually
• In some system, for example, CP-F-RASS, TCP changes relative • Steps to release a gripper manually with example CP-F-RASS
to the gripper. model.
1. Move the robot arm to the desired position.
• Steps to mount a gripper manually with example CP-F-RASS 2. In Teach-In panel → Gripper output, open HClose_3.
model. 3. Start simulation (F5).
4. Stop simulation (F5).
1. Select <Automatic TCP>. 5. The gripper is released.
2. Move the robot arm to the tool position.
3. In Teach-In panel → Gripper output, close HClose_3.
4. Start simulation (F5).
5. Stop simulation (F5).
6. The gripper is mounted.

212
TCP Tracking
• TCP path of robot movement can be monitored.
• Active TCP tracking from View → TCP tracking.

213
View TCP Coordinate
• Joint coordinate and cartesian coordinate of the active TCP can be monitored.

214
Robot Workspace
• The room that TCP can reach.
• Activate at View → Robot workspace.

215
Collision Detection
• Collision detection can be activated.
• In collision detection mode the movements are always
incremental.
• It is useful in testing a new robot program to avoid collision.

216
Collision Detection
Configuration (1)

1. Assign group. Collision is only detected when elements in deferent 4. Assign content to Rest group.
groups cross each other.
1. Select Settings → Collision detection.

2. In Collision Detection window, select Manage collision groups.

3. Assign content to Roboter group.

217
Collision Detection
Configuration (2)

2. Assign the collision group pair.

1. Close Manage collision groups window.
2. Select Roboter as group 1 and Rest as group 2.
3. Move the pair to the right to activate it.
4. Select OK.

218
Collision Detection
Activate simulation

1. Select Simulation → Collision detection.

2. Move the robot against an object and observe the simulation.

219
 Only CIROS Studio
Connect to Robot Controller
Communication interface

• Ethernet cable
• TCP/IP protocol
• IP-Address and Port

LAN Port

220
 Only CIROS Studio
Check the Ethernet Cable
Please check the ethernet connection between robot controller and the computer.

221
 Only CIROS Studio
Connect to Robot Controller
Find the IP-address from R32TB

1. The IP-address can be read from robot teach box (TB). 4. Select 3.PARAM.

2. Exit everything until home page.

5. Search for parameter NETIP. Read the IP-address.

3. Press F1 to enter menu.

222
 Only CIROS Studio
Connect to Robot Controller
Find the IP-address from R56TB

1. The IP-address can be read from robot teach box (TB). 3. Click on “Parameter name” to search for parameter “NETIP”.

2. Select “Parameter” from the menu. 4. Key in “NETIP” and click “Enter”.

5. IP Address is shown.

Video Tutorial: 53_FindMitsuIpR56TB.mp4

223
 Only CIROS Studio
Connect to Robot Controller
Change the IP-address of the computer to the same network

1. Open network adapter properties. 3. Select Properties.

4. Change the IP address to the same network as robot
controller.

2. Select Internet Protocol Version 4 (TCP/IPv4).

224
 Only CIROS Studio
Connect to Robot Controller
Set robot controller to Automatic and switch of teach mode.

225
 Only CIROS Studio
Connect to Robot Controller
Insert CP-F-RASS model

1. Create a new CIROS project.

2. Insert “CP-F-RASS_Mitsubishi” from Festo CP System model
library.
Video tutorial: 54_InsertCP-F-RASS.mp4
3. Optional: To hide robot housing, in Model Explorer, select
“Geometrie\Geometrie_Umhausung”. In
Properties\Visualization, select “Invisible”.
Video tutorial: 56_HideHousing.mp4

226
 Only CIROS Studio
Connect to Robot Controller
Configure communication setting

1. In Model Explorer, select “CP-F-RASS_Mitsubishi\Montage_RV-4FL”. 4. Expand Communication in properties window and select TCP/IP.
2. In properties window, select Communication. 5. Enter the IP-address of the robot controller.
3. Select TCP/IP as connection type. 6. Port = 10001

Video tutorial: 57_ConnectMitsuRobot.mp4

227
 Only CIROS Studio
Connect to Robot Controller
RCI-Explorer

• RCI = Robot Control Interface

• Allow user to read information, program and control the robot controller in CIROS.
• Can create / load robot controller backup.
Online /
• Edit the program by uploading the robot program into local workspace. Robot controller

Offline / Local

228
Only CIROS Studio
Connect to Robot Controller
Open RCI-Explorer

• Select Extras > Online management > RCI explorer…

229
 Only CIROS Studio
Connect to Robot Controller
Build the connection

1. In RCI Explorer, right click on Connection and select Connect. 4. Connection is established.

2. Please pay attention to the security advice and environment of real

robot!
3. Select OK when the window pops up.

Video tutorial: 57_ConnectMitsuRobot.mp4

230
Only CIROS Studio
Online Information from Robot Controller
Robot type

231
Only CIROS Studio
Online Information from Robot Controller
Robot programs

232
 Only CIROS Studio
Online Information from Robot Controller
Robot programs in slots

233
Only CIROS Studio
Online Information from Robot Controller
System variables

234
Only CIROS Studio
Online Information from Robot Controller
Parameters

235
Only CIROS Studio
Read Live Parameter Value

236
 Only CIROS Studio
Online Information from Robot Controller
Error list

237
 Only CIROS Studio
Online Information from Robot Controller
Refresh window

• Sometimes, the window is not updated. In this case, the

windows can be refreshed.

Video tutorial: 58_RefreshRCIWindow.mp4

238
 Only CIROS Studio
Create Robot Controller Backup
1. Right click on the robot and select Create backup\All. 2. Confirm the warning.

3. Creating backup…

2. Create the backup in an empty folder.

Video tutorial: 59_CreateRobotBackup.mp4

239
 Only CIROS Studio
Robot Controller Backup Folder
• By default, backup is located in <project folder>\Backup.

240
 Only CIROS Studio
Load Backup

1. Right click on the robot and select Load backup > All. 2. Select backup folder.
3. Restart the controller after loading complete.

241
 Only CIROS Studio
Upload Robot Programs

• Robot programs can be uploaded to the computer.

• Uploaded programs are listed in Workplace\Programs.
• The programs can then be edited.

242
 Only CIROS Studio
Upload Robot Programs
1. In RCI Explorer, right click on Programs, select Upload all. 3. Programs which are running in slots cannot be uploaded. Click ok and
continue uploading the missing programs.

2. When this window pops out, click ok.

Video tutorial: 60_UploadRobotPrograms.mp4

243
 Only CIROS Studio
Robot Program Folder
• By default, uploaded robot programs are located in <project
folder>\<robot controller name>.
• For example,
• CIROS project : RASS2_717
• Robot name : Montage_RV-4FL
• Uploaded robot programs are located in ..\RASS2_717\Montage_RV-
4FL.

244
 Only CIROS Studio
Download Program

• Programs in Workspace can be downloaded into robot controller.

1. Select the MB5 program in workspace.

2. Right click and select Download.

245
 Only CIROS Studio
Online Teach-In
• Once connected, it is possible to activate online teaching in Teach-In panel.
• Online teaching mode allows
• Simulation of real time robot position in CIROS
• Move the real robot in CIROS
• Track the real robot coordinates in CIROS

1. Activate online teaching.

2. Observe the change in model window.
3. Move Roll coordinate of the robot incrementally 5°.
4. Deactivate online teaching.
5. Reset the model.

246
 Only CIROS Studio
Online Teach-In
1. Make sure robot controller is online. 4. At the bottom of Teach-In panel, click on Activate online
2. Open Teach-In panel. teaching.
Shortcut: F8

5. Click ok on pop-up window.

3. Select the robot as active controller.

Video tutorial: 61_RobotTeachIn.mp4

247
 Only CIROS Studio
Online Teach-In
Notice the difference between before and after teach in is activated.

248
 Only CIROS Studio
Get Actual Robot Data with Built-In Python Function
1 3

Ready to use project: robotInfo.py

Video tutorial: 62_RobotInfoPython.mp4
249
Virtual Reality
Setting up VR Glasses

• CIROS can be directly connected to VR glasses like HTC Vive and Oculus Rift.
• Typical procedure
1. Install Steam / SteamVR and create a user account (https://store.steampowered.com/)
2. Start Steam and switch to “offline mode” in case that Steam should be used without internet access
3. Start SteamVR and run room setup
4. Configure the VR mode of CIROS
5. Activate VR mode of CIROS and start the simulation

Note: HTC Vive is the only officially supported VR glasses.

Switching between Steam’s online/offline mode

251
Setting up VR Glasses Configuration of the (virtual) room
Start SteamVR and run Room Setup

Name of the application

currently using SteamVR

Filled icons represent active components

List of available HTC Vive components (from left to right):

Glasses, controller 1 & 2, left & right base station
252
Setting up VR Glasses
Start SteamVR and run Room Setup

Choose “Room-Scale” to be
able to go around in the real
and virtual room

253
Setting up VR Glasses
Start SteamVR and run Room Setup

Calibrate real and virtual floor

(ground level wrt. to z-axis)

254
Setting up VR Glasses
Start SteamVR and run Room Setup

Configuration of the available physical

space to be matched with the virtual room

255
Setting up VR Glasses
Start SteamVR and run Room Setup

Specify the available physical space (its

outer perimeter) by holding the trigger
button of one of the two controllers

256
 Setting up VR Glasses
Start SteamVR and run Room Setup

If the available space defined before fits

the “Play Area” it will be highlighted in
green

Direction of the user perspective onto the

SteamVR scene

“EDIT” allows for optimizing position,

size, and user perspective manually

257
Setting up VR Glasses
Configure VR mode of CIROS

1. Select File → Application options.

2. Configure VR devices.

Enable VR glasses

“Seated” should be used in cases in which

“Standing” corresponds to “Standing Only” has been selected during
SteamVR‘s “Room Scale” SteamVR’s room setup

List of available/connected VR sets

258
Setting up VR Glasses
Configure VR mode of CIROS

3. Select Settings → Model options

4. Set the simulation increment to 0.011s, since the HTC
Vive can perform 90fps
5. Let the simulation run as fast as possible
6. Switch the standard views to default setting

259
Setting up VR Glasses
Activate VR mode of CIROS and start the simulation

• Enable the connected VR device and start the simulation

• Remark: It is highly recommended to disable all shadow
calculations to have enough computational power for a
“smooth” visualization!

260
Interact with Model
• To interact with the model, for example, click on the buttons,
start and stop simulation, etc. An interactive element has to be
added.

1. Go to “Modelling → Model libraries”.

2. Expand “Interactive elements”.
3. Add “Virtual Reality controller”.

• Note: “Simulation Control” has to be shown in “Model

Window” to be able to control simulation in VR.
Advanced
Move I/O Address
Example: Moving digital input S1_A from bit 3 to 11 (1)

1. Open “Model Explorer”.

2. Go to the input to be moved.
MPS Robot Station → Objects → MPSRobotStation → RV-2F → Inputs
3. Right click on destination address, and select “Rename”.
4. Assign a name, note that names of the cannot repeat in the whole
model, add an extension such as “_1” at the end if needed.

5. If the input is connected to an output, it has to be reconnected. Double

click on original address to open it, right click on “Connected output”
and select “Follow connection”.

263
Move I/O Address
Example: Moving digital input S1_A from bit 3 to 11 (2)

6. Now the connected output is shown, select the output, drag

and drop it to the new address to connect them.
In Model Explorer, drag “MPS Robot Station → MPSRobotStation →
Trolley700 → Panel → PushButtonStart → Outputs → Start” and drop
to “MPS Robot Station → MPSRobotStation → RV-2F → Inputs →
S1_A_1”
7. Deactivate the old address by right click, select Edit →
Deactivate.

8. Rename the destination input back.

9. Update the programs which use the bit.

Video tutorial: 43_MoveIOs.mp4

264
Export as High-Resolution Images
• File → Export enables the user to save the content of the so-called “first” view window as a high-resolution PNG file.
3
2

265
Multiple View Windows
• CIROS is not restricted to a single view window but offers the possibility to show a couple of view windows concurrently.
• To open a new window, select View → New window.
• Each view might have a different perspective onto the scene.

First / main view window Additional view windows

266
CIROS Starter
Calling CIROS model with URL

Possible action Parameter Explanation

Start simulation StartSimulation Starts the simulation.

Activate full screen ActivateFullScreen Runs CIROS in in full screen mode.

Use single instance UseSingleInstance CIROS uses an existing instance to open the new
model. A new instance is only started if no
instance of CIROS is running yet.

URL format:
“StartCIROS: <path to model>?Parameter1&Parameter2”

Example:
"StartCIROS:Example Models\Small Demos for Learning\Robot Assembly with UR5\Robot Assembly with UR5.modx?ActivateFullScreen&UseSingleInstance"

267
Model Analysis
Extras → Model analysis → Whole model

• Help in problem diagnosis and finding a solution

Note: Picture in German.

268
CIROS Part Number for CP System
“PartNrReplikator.py” replicates the part in simulation. “PartNrTranslation.py” translates MES4 part number to CIROS part number.

Digit 6 Digit 5 – 3 Digit 2 Digit 1 Digit 0

Special parts Parts Fuses Front cover colours Back cover colours
Pallet 1 Unprocessed front cover 1 Front fuse 1 Black 0 Black 0
Front cover, raw block 2 Front cover 2 Rear fuse 2 Grey 1 Grey 1
Back cover, 3 PCB 4 Blue 2 Blue 2
not pressed on front cover
Turn part 4 Back cover 8 Red 3 Red 3
Boxes 5 Label on front cover 16 Not used 4 Not used 4
Not used 6 Label on back cover 32 Not used 5 Not used 5
Not used 7 Not used 64 Not used 6 Not used 6
Not used 8 Not used 128 Not used 7 Not used 7
Not used 9 Not used 256 Not used 8 Not used 8

Example: see picture

0 2+4+8 1+2 2 3 = 0014323 = 14323

269
Create Own Part
Task: Add a MPS Part from CP-L-SOURCE

• There are some parts supported from CP-System model libraries. It is possible to create own part to work in CP environment in
CIROS.
• User can import the CAD drawing of their parts and test it in virtual environment before implementing it on the real system.
• Steps to create own part will be explained with an example of adding a Festo MPS red housing with RFID and black MPS cap to a
CP-L-CONVEYOR via a CP-L-SOURCE.

270
Create Own Part
MPS part numbers according to FactoryViews[1]

Part Part Image Part Part Image

number number
3001 Red MPS housing with 3020 Black cap
RFID

3002 Black MPS housing with 3080 Cap with integrated micro-
RFID controller

3003 Silver MPS housing with

RFID

[1] FactoryViews is the new software bundle for MES and web based services. It contains MES4 v3. 271
Create Own Part
Steps to create an own part (1)

1. Prepare CAD drawing of the parts in supported format. (→)

2. Define MES4 / FactoryViews part numbers. (→)
3. Define CIROS part numbers. (→)
4. In CIROS, create a new project and import the CAD drawing. (→)
5. If needed, optimize the geometry of the CAD drawing to reduce its size and rendering requirement in simulation. (→)
6. Rename the object and configure its properties, such as object type, gripper points and grip points. (→) (→)
7. Define coordinates of gripper points and grip points in the model, so the parts are replicated and snapped in correct place in simulation. (→)
8. Move the configured object to Templates by drag and drop. (→)
9. Insert following CP-System Models from Model Libraries and snap them to place.
• CP-L-CONVEYOR, CP-L-SOURCE and CP-L-SINK
10. Modify following files to add new part numbers.
<project>\CF\py\PartNrTranslator.py (→) and <project>\CF\py\PartNrReplikator.py (→)
11. Modify template “Palette” to allow it to take along new parts during transportation. (→)
12. Add following objects to “Objects → Werkstuecke”. These are the meta objects.
• Housing, Pistons and Caps
13. Save all, close CIROS and restart CIROS. Then, open the project and test the new parts added.

272
Create Own Part
Prepare CAD drawing of the parts in supported format.

• CIROS supported formats are as follow:

• 3ds Max
• AutoCAD DXF
• Autodesk
• Blender
• Collada
• IGES
• PointCloud
• STEP
• STL
• VRML
• Wavefront Object

273
Create Own Part
Define MES4 / FactoryViews part numbers.

Part number Part

1 MPS housing red
2 MPS housing black
3 MPS housing silver
3001 Red MPS housing with piston containing RFID chip
3002 Black MPS housing with piston containing RFID chip
3003 Silver MPS housing with piston containing RFID chip
3020 MPS cap
13001 Red MPS housing + piston + cap
13002 Black MPS housing + piston + cap
13003 Silver MPS housing + piston + cap

274
Create Own Part
CIROS part number as defined in “PartNrTranslation.py”

Digit 6 Digit 5 – 3 Digit 2 Digit 1 Digit 0

Special parts Parts Fuses Front cover / housing Back cover/cap
colours colours
Pallet 1 Unprocessed front cover 1 Front fuse 1 Black 0 Black 0
Front cover, raw block 2 Front cover 2 Rear fuse 2 Grey 1 Grey 1
Back cover, 3 PCB 4 Blue 2 Blue 2
not pressed on front cover
Turn part 4 Back cover 8 Red 3 Red 3
Boxes 5 Label on front cover 16 Not used 4 Not used 4
Not used 6 Label on back cover 32 Not used 5 Not used 5
Not used 7 MPS housing 64 Not used 6 Not used 6
Not used 8 MPS piston 128 Not used 7 Not used 7
Not used 9 MPS cap 256 Not used 8 Not used 8

Example: see picture

0 64+128+256 0 3 0 = 0 448 0 3 0 = 448030
275
Create Own Part
Import CAD drawing
1 2

276
Create Own Part
Optimize geometry

1. Select the imported CAD object in Model Explorer.

2. Click Modeling → Geometry optimization [1] .
3. Run the required optimizations.

• In the example, following optimizations were carried out. 1

• Clean up geometry [2]

• Merge hulls with matching material or area color [3] 2

• Simplify object hierarchy [4]

277
Create Own Part
Objects’ properties defined in example.

Part name Meta object Object type Gripper points Grip points
MPS_Housing_rt [1] Housing WS GripPistonRed HousingRed
GripCapRed
MPS_Housing_sw [2] Housing WS GripPistonBlack HousingBlack
GripCapBlack
MPS_Housing_gr [3] Housing WS GripPistonSilver HousingSilver
GripCapSilver
MPS_Piston Pistons WS PPiston
MPS_Cap Caps WS CapStackBlackCap

[1] rt = red (German: rot)

[2] sw = black (German: schwarz)
[3] gr = grey, in this case silver (German: grau)
278
Create Own Part
Configure object’s properties in CIROS (1)

1. Rename the object in Model Explorer. 4. Configure gripper points.

1. Select gripper point. In Properties → Mechanism, select Type as Take along.
2. Set value of Grip only objects in direct meta object(s) to the object laying in
or on top of the part. Click Apply.
2. Configure object type.
Example: Black MPS Housing, the value is Pistons, Caps. Because these parts lay in
1. In Properties, select General → Object type.
and on top of the housing.
2. In Change field, type in ‘WS’.
Hint: The value can be written directly in the field below.

3. Add gripper points.

1. In Model Explorer, right click on MPS_Housing_sw → Base and select New
→ Gripper point.

2. Rename the gripper points.

279
Create Own Part
Configure object’s properties in CIROS (2)

5. Add grip point.

1. Right click on Base, select New → Grip point.

2. Rename the grip point.

280
Create Own Part
Define coordinates of gripper points and grip points.

• The x, y, z-coordinates of the parts have to match, so that the

parts replicated can be snapped in the right place.
• X, y, z-coordinates in CIROS are highlighted in different colours.
Z
Y

• Coordinates of gripper and grip points can be moved in

Properties → Pose.

281
Create Own Part
Move configured object to Templates.

• Objects can be moved between ‘Objects’ and ‘Templates’ in Model Explorer by drag and drop.

282
Create Own Part
“PartNrTranslation.py” description

• “PartNrTranslation.py” translate MES4 part number to CIROS • List “CirosPN_by_PNsw” translates MES part number to CIROS
part number. part number. Only part number of black part is needed here.
• 2D array “PN_by_color” sorts the part by colour.

• Attention: Part row of “PN_by_color” must match with

“CirosPN_by_PNsw” for the script to find the correct part!
283
Create Own Part
Add new parts to “<project>\CF\py\PartNrTranslation.py”

1. Add MES part numbers to “PN_by_color”. 2. Add part numbers to “CirosPN_by_PNsw”.

• Note that the part rows of “PN_by_color” matches

“CirosPN_by_PNsw”.

284
Create Own Part
“PartNrReplikator.py” description

• “PartNrReplikator.py” takes the translated CIROS part number • “bauteil_ID” contains detailed information of each CIROS ID.
and replicates the part in the model from templates.
• The script also configures gripper points and grip points.

• List “farbe_ID” matches colour ID[1] in “PartNrTranslator.py”

with colour add on at the end of templates name[2].

• “sonderteil_ID” contains detailed information of CIROS ID

which are declared as special parts.
1 2

285
Create Own Part
Add new parts to “<project>\CF\py\PartNrReplikator.py”

1. Add new parts to list “bauteil_ID”.

2. In function “replicatePartAt”, under “elif bauteile:”, add “or id

== 64”, to allow colour allocation of MPS housings. At
default v7.1 script it is at line 123.

286
Create Own Part
Modify template “Palette”

1. Move “Palette” from “Templates” to “Objects”. 3. In Properties window, change the value of “Grip only objects in direct
meta object” to “Frontschalen,Ruechschalen,Housing” and click Apply.
Note: The value can be typed directly in the field below.

2. Select “Palette → _347490-d_Palette_110x164mm → Gripper points

→ Bauchlage_Palette”.

4. Move “Palette” back to “Templates”.

287
Create Own Model Library
• There are model libraries with a huge variety of models by default. However, these models are encrypted and not editable.
• It is possible to create own libraries, either from scratch or from modified standard model libraries. These libraries created can be
edited from time to time and can also be used as a building block to build own models, just like the standard model libraries.
• In coming tutorials, steps to create own model libraries from modified standard model libraries containing a modified CP-L-
CONVEYOR, CP-L-SOURCE and CP-L-SINK which supports MPS workpiece will be shown. Steps to create MPS workpiece in CP
environment is shown in previous chapter.

• Important! If the library is made from modified standard library, avoid mixing new model library with standard library for an error
free simulation.

288
Create Own Model Library
Elements of a model library

• CF.7z
• Textures.7z
• Model
• Model.modx
• Model.png
• Model.ini
• Model.html
• InitModBib.modx
• InitModBib.ini
• InitModBib.fin

289
Create Own Model Library
Steps to create own model library

1. Create CF.7z and Textures.7z.

2. Create InitModBib (*.fin, *.ini and *.modx).
3. Create the models.
4. Link the model library in CIROS.

290
Create Own Model Library
Create CP.7z and Textures.7z

1. In a chosen window’s path, create an empty folder. This will be the new model library folder.
2. In CIROS Studio, create a CIROS model in the folder created above. Name it InitModBib.modx.
3. Add any model from Festo CP System model library.
4. Delete all Materials in Model Explorer.
5. In <project folder>\CF, replace any modified python or irl scripts.
6. Compress following folders with 7-Zip:
1. <project folder>\CF
2. <project folder>\Textures

291
Create Own Model Library
Create InitModBib (*.modx, *.ini and *.fin)

1. Go to CIROS project created (InitModBib.modx).

2. Make sure Model Explorer → Templates contains all the parts required in the new model library.
Note: Import the part as an object to CIROS model and convert it into template if required.
3. Make sure Model Explorer → Objects → Werkstuecke contains all the meta objects required in new model library.
4. In Model Explorer, delete all objects except “Werkstuecke”.
5. In Model Explorer, delete all materials.
6. Save all.

292
Steps to Create own Virtual Machine Communicating with MES4
• At the end of this tutorial, a resource consists of a belt with
application module traffic light is created (see picture on the
right) and is able to work together with a CP-L-CONVEYOR.

• The module can work in default mode and MES mode.

• In default mode, red, yellow and green LEDs will light up one
after another.
• In MES mode, the LED configured in MES will light up.

293
Steps to Create own Virtual Machine Communicating with MES4
Steps to create base module.

1. Insert CP-L-CONVEYOR from Festo CP System model library. 5. Delete following components in ConveyorBelt.
• LedBackwards
2. Insert ModLibs\Conveyors\ConveyorBelt. • LedForwards
• LedStopped
• ProfilesTopX
• All inputs
• All outputs

3. Delete all Extended properties in Properties\Extended. 6. Go to Properties\General, select object type as Inactive object.
7. Go to Modelling\Geometry optimization.
8. Select Merge hulls with matching material or area color to optimize
ConveyorBelt.

4. Add following extended properties.

Key Value
CT_Type PassiveObject
CT_System TransferFactory
CT_Assembly 1
294
Steps to Create own Virtual Machine Communicating with MES4
Steps to create base module.

7. Change the size of ConveyorBelt in Properties\Dimension. 10. Copy CP-L-CONVEYOR\SPS_A and paste it under object ConveyorBelt.
• X = 700 mm The object is renamed to SPS_A_1.
• Y = 120 mm
• Z = 974.50 mm 11. Change position of SPS_A_1 in world coordinate.
• X = 350 mm
• Y = 54.55 mm
• Z = 975 mm
12. Copy CP-L-CONVEYOR\Conn1 and Conn2 and paste them under
ConveyorBelt.

Hint: Use prepared CAD model “ConveyorBelt.stp” to skip step 2, 3, 5 and

7. Please request the CAD model from Festo Didactic.

295
Steps to Create own Virtual Machine Communicating with MES4
Steps to create base module.

13. Move ConveyorBelt\Conn1 and Conn2 to right and left end of

ConveyorBelt respectively.
Object coordinate X [mm] Y [mm] Z [mm]
Conn1 0 54.55 975
Conn2 700 54.55 975

14. Select object ConveyorBelt. Go to Properties\Connectors. Add

following connectors and triggers.

296
Steps to Create own Virtual Machine Communicating with MES4
Steps to create base module.

15. Go to SPS_A_1\Inputs, connect DIN1_x5 to 1. 19. Right click on Projects\CPSystem_Allgemein(IRL) and compile the
project. Make sure that all projects are compiled successfully.
20. Drag and snap ConveyorBelt to CP-L-CONVEYOR.
21. Base module is created.

16. Open Project Management.

17. Open project <project folder>\CF\CPSystems\CPSystem_Allgemein.prjx.
18. In Controllers\SPS_A_1, assign CPSystem_Allgemein. Do the same for
SPS_A.

297
Steps to Create own Virtual Machine Communicating with MES4
Steps to create application module.

1. In model libraries, insert LEDs and switches\Signal lights. 3. Move origin of SignalLights to middle bottom of the object.
Hint: With help of 3D marker.

2. Select SignalLights, in Properties\General, change object type to Work 4. Change z-coordinate of SignalLights in world coordinate to 975 mm.
station. 5. Add analog output and name it CIROS_App_ID.

298
Steps to Create own Virtual Machine Communicating with MES4
Steps to create application module.

6. Select SignalLights, add following extended property. 9. Move AppConn pose to front middle of object’s bottom plane.
Key Value
OF OUT_CIROS_App_ID := 24

7. In CP System model library, add any application module, for example,

CP-AM-MAG_FRONT.
8. Copy CP-AM-MAG_FRONT\AppConn and paste it under object
SignalLights.

299
Steps to Create own Virtual Machine Communicating with MES4
Steps to create application module.

10. Select SignalLights, in Properties\Connectors, configure connectors

and triggers as follow.

300
Steps to Create own Virtual Machine Communicating with MES4
Steps to program virtual machine in IRL

1. Add app ID to “Applikationen.irl”.

1. In “Project Management\Projects\CPSystem_Allgemein(IRL)\Files”, open
“Applikationen.irl”.
2. In Function “App()”, add following line,
if( applicationID = 24 ) then return( appSignalLights( mes.Parameter ) ); endif;

301
Steps to Create own Virtual Machine Communicating with MES4
Steps to program virtual machine in IRL WAIT 1.0 SEC;
YellowOn := false;
GreenOn := true;
2. Add function “appSignalLights()” to Applikationen.irl. else
FUNCTION appSignalLights( IN ARRAY [1..7] OF REAL: Parameter ) : int; redMES := Parameter[1];
VAR yellowMES := Parameter[2];
INPUT BOOL : RedIsOn AT 0; greenMES := Parameter[3];
INPUT BOOL : YellowIsOn AT 1; IF redMES = 1 THEN
INPUT BOOL : GreenIsOn AT 2; RedOn := true;
OUTPUT BOOL : RedOn AT -1; ENDIF;
OUTPUT BOOL : YellowOn AT 0; IF yellowMES = 1 THEN
OUTPUT BOOL : GreenOn AT 1; YellowOn := true;
REAL : redMES; ENDIF;
REAL : yellowMES; IF greenMES = 1 THEN
REAL : greenMES; GreenOn := true;
BEGIN ENDIF;
RedOn := false; endif;
YellowOn := false;
GreenOn := false; WAIT 1.0 SEC;
if( MyResourceId = 0 ) then RedOn := false;
{Standardmode} YellowOn := false;
RedOn := true; GreenOn := false;
WAIT 1.0 SEC;
RedOn := false; return (0);
YellowOn := true; ENDFCT;
302
Steps to Create own Virtual Machine Communicating with MES4
Steps to program virtual machine in IRL

3. Save the program.

4. Compile the project and make sure that all projects are compiled successfully.
5. A resource with base and application module is created.

303
Troubleshoot in External Document
CIROS-CP_Troubleshoot_EN_v7.1_xxxxxx.pdf