GAUGE I/O DIAGRAM 6037404679

Mahindra (India)
M110 Meas. Station
WBE M232001
Proj
KIT CM20009112

Revisions history
Date Rev. Description Author Approved
16 August 2023 - New template John Gu Aontonietta M.
6 November 2023 A Change to Modbus communicate with PLC John Gu Aontonietta M.

I/O card list

Type Conn. Fieldbus data (node, addr, etc.) IN/OUT bytes PLC addr.
Profinet Device Exp.Slot marpossdev 64Out/64In (*) 192.168.0.1
PLC programming order
Siemens S1500: OUT 128 - IN 128
File for PLC Master
GSDML-V2.32-HILSCHER-CIFX RE PNS-20160502.xml

#VALUE!
Author : John Gu General Revision -
Approved : Page 1/21
 E9066 I/O CONFIGURATION 6037404679

M232001 Mahindra HW CONNECTION SCHEME

Electrical Cabinet

DC24V Adapter AC220V

USB 1
3
1
LAN3 HUB
Modbus

LAN1 LAN2 LAN4 MES

192.168.0.10

10m

2
3m

ETH 24Vdc IN 24Vdc IN

192.168.0.1
DC24V 3A

72 LVDT ；
4 Heidenhain Optical ruler;
1 Heidenhain Encoder;
1 Amnient temperature probe;
1 Part instant temperature probe;

# Code Qty. Unit Description Brand Charge

1 B8667J01512 1 pcs E66TF-15S0 5-7440 8 256 PND UPS W10 IP54 Bench (Use M225004 Left) MARPOSS NNA
2 B8668A07521 1 pcs GP ETH 1E 2D 2G (Use M225608 left, and added 3 pcs 16DAQ) MARPOSS MNA
3 Z4702516013 1 pcs K400 PLUS LOGITECH MNA

Author : John Gu Connection Revision -

Approved : Page 2/21
 GAUGE I/O DIAGRAM 6037404679

PLC GAUGE DESCRIPTION PLC GAUGE DESCRIPTION

AUTOMATIC AUTOMATIC ECHO
Q #VALUE! IN 01 I #VALUE! OUT 01
DRYRUN GAUGE EFFICIENT
Q #VALUE! IN 02 I #VALUE! OUT 02
GAUGE CAPABILITY ACTIVE
Q #VALUE! IN 03 I #VALUE! OUT 03
CALIBRATION CALIBRATION REQUEST
Q #VALUE! IN 04 I #VALUE! OUT 04

Q #VALUE! IN 05 I #VALUE! OUT 05

Q #VALUE! IN 06 I #VALUE! OUT 06

Q #VALUE! IN 07 I #VALUE! OUT 07

Q #VALUE! IN 08 I #VALUE! OUT 08

STROBE OUTSIDE TRANSDUCERS TEST ACK OUTSIDE TRANSDUCERS TEST
Q #VALUE! IN 09 I #VALUE! OUT 09
STROBE PART LOAD ACK PART LOAD
Q #VALUE! IN 10 I #VALUE! OUT 10
STROBE INSIDE TRANSDUCERS TEST ACK INSIDE TRANSDUCERS TEST
Q #VALUE! IN 11 I #VALUE! OUT 11
STROBE START STEP ACK START STEP
Q #VALUE! IN 12 I #VALUE! OUT 12
END OF ACQUISITION
Q #VALUE! IN 13 I #VALUE! OUT 13
STROBE END OF CYCLE ACK END OF CYCLE
Q #VALUE! IN 14 I #VALUE! OUT 14
STROBE STATISTIC ELABORATION END STATISTIC ELABORATION
Q #VALUE! IN 15 I #VALUE! OUT 15

Q #VALUE! IN 16 I #VALUE! OUT 16

PART TYPE CODE x 1 GOOD PART
Q #VALUE! IN 17 I #VALUE! OUT 17
PART TYPE CODE x 2 REWORK PART
Q #VALUE! IN 18 I #VALUE! OUT 18
PART TYPE CODE x 4 REJECT PART
Q #VALUE! IN 19 I #VALUE! OUT 19
PART TYPE CODE x 8 INVALID PART
Q #VALUE! IN 20 I #VALUE! OUT 20
PART TYPE CODE x 16
Q #VALUE! IN 21 I #VALUE! OUT 21
PART TYPE CODE x 32
Q #VALUE! IN 22 I #VALUE! OUT 22
PART TYPE CODE x 64
Q #VALUE! IN 23 I #VALUE! OUT 23
PART TYPE CODE x 128
Q #VALUE! IN 24 I #VALUE! OUT 24

Author : John Gu Profinet Revision -

Approved : Page 3/21
 GAUGE I/O DIAGRAM 6037404679

PLC GAUGE DESCRIPTION PLC GAUGE DESCRIPTION

MEASURE STEP CODE x 1
Q #VALUE! IN 25 IB #VALUE! OUT 25
MEASURE STEP CODE x 2
Q #VALUE! IN 26 IB #VALUE! OUT 26
MEASURE STEP CODE x 4
Q #VALUE! IN 27 IB #VALUE! OUT 27
MEASURE STEP CODE x 8
Q #VALUE! IN 28 IB #VALUE! OUT 28
MEASURE STEP CODE x 16
Q #VALUE! IN 29 IB #VALUE! OUT 29
MEASURE STEP CODE x 32
Q #VALUE! IN 30 IB #VALUE! OUT 30
MEASURE STEP CODE x 64
Q #VALUE! IN 31 IB #VALUE! OUT 31
MEASURE STEP CODE x 128
Q #VALUE! IN 32 IB #VALUE! OUT 32

Q #VALUE! IN 33 IB #VALUE! OUT 33

STROBE SEND MARKING DATA ACK SEND MARKING DATA END
Q #VALUE! IN 34 IB #VALUE! OUT 34

Q #VALUE! IN 35 IB #VALUE! OUT 35

Q #VALUE! IN 36 IB #VALUE! OUT 36

Q #VALUE! IN 37 IB #VALUE! OUT 37

Q #VALUE! IN 38 IB #VALUE! OUT 38

Q #VALUE! IN 39 IB #VALUE! OUT 39

Q #VALUE! IN 40 IB #VALUE! OUT 40

PART SERIAL CODE BYTE 1 OUT_TX_BYTE1
QB #VALUE! INB 41 ASCII CODE
IB #VALUE! OUTB 41
PART SERIAL CODE BYTE 2 OUT_TX_BYTE2
QB #VALUE! INB 49 ASCII CODE
IB #VALUE! OUTB 49
PART SERIAL CODE BYTE 3 OUT_TX_BYTE3
QB #VALUE! INB 57 ASCII CODE
IB #VALUE! OUTB 57
PART SERIAL CODE BYTE 4 OUT_TX_BYTE4
QB #VALUE! INB 65 ASCII CODE
IB #VALUE! OUTB 65
PART SERIAL CODE BYTE 5 OUT_TX_BYTE5
QB #VALUE! INB 73 ASCII CODE
IB #VALUE! OUTB 73
PART SERIAL CODE BYTE 6 OUT_TX_BYTE6
QB #VALUE! INB 81 ASCII CODE
IB #VALUE! OUTB 81
PART SERIAL CODE BYTE 7 OUT_TX_BYTE7
QB #VALUE! INB 89 ASCII CODE
IB #VALUE! OUTB 89
PART SERIAL CODE BYTE 8 OUT_TX_BYTE8
QB #VALUE! INB 97 ASCII CODE
IB #VALUE! OUTB 97
PART SERIAL CODE BYTE 9 OUT_TX_BYTE9
QB #VALUE! INB 105 ASCII CODE
IB #VALUE! OUTB 105
PART SERIAL CODE BYTE 10 OUT_TX_BYTE10
QB #VALUE! INB 113
ASCII CODE
IB #VALUE! OUTB 113
PART SERIAL CODE BYTE 11 OUT_TX_BYTE11
QB #VALUE! INB 121
ASCII CODE
IB #VALUE! OUTB 121
PART SERIAL CODE BYTE 12 OUT_TX_BYTE12
QB #VALUE! INB 129
ASCII CODE
IB #VALUE! OUTB 129
PART SERIAL CODE BYTE 13 OUT_TX_BYTE13
QB #VALUE! INB 137
ASCII CODE
IB #VALUE! OUTB 137
……
QB #VALUE! INB …
ASCII CODE
IB #VALUE! OUTB …
PART SERIAL CODE BYTE 31 OUT_TX_BYTE31
QB #VALUE! INB 281
ASCII CODE
IB #VALUE! OUTB 281
PART SERIAL CODE BYTE 32 OUT_TX_BYTE32
QB #VALUE! INB 289
ASCII CODE
IB #VALUE! OUTB 289

Author : John Gu Profinet Revision -

Approved : Page 4/21
 GAUGE I/O DIAGRAM 6037404679

PLC GAUGE DESCRIPTION PLC GAUGE DESCRIPTION

OUT_TX_BYTE33
QB #VALUE! INB 290 IB #VALUE! OUTB 290
OUT_TX_BYTE34
QB #VALUE! INB 298 IB #VALUE! OUTB 298
OUT_TX_BYTE35
QB #VALUE! INB 306 IB #VALUE! OUTB 306
OUT_TX_BYTE36
QB #VALUE! INB 314 IB #VALUE! OUTB 314
OUT_TX_BYTE37
QB #VALUE! INB 322 IB #VALUE! OUTB 322
OUT_TX_BYTE38
QB #VALUE! INB 330 IB #VALUE! OUTB 330
OUT_TX_BYTE39
QB #VALUE! INB 338 IB #VALUE! OUTB 338
OUT_TX_BYTE40
QB #VALUE! INB 346 IB #VALUE! OUTB 346
OUT_TX_BYTE41
QB #VALUE! INB 347 IB #VALUE! OUTB 347
OUT_TX_BYTE42
QB #VALUE! INB 355 IB #VALUE! OUTB 355
OUT_TX_BYTE43
QB #VALUE! INB 363 IB #VALUE! OUTB 363
OUT_TX_BYTE44
QB #VALUE! INB 371 IB #VALUE! OUTB 371
OUT_TX_BYTE45
QB #VALUE! INB 379 IB #VALUE! OUTB 379
OUT_TX_BYTE46
QB #VALUE! INB 387 IB #VALUE! OUTB 387
OUT_TX_BYTE47
QB #VALUE! INB 395 IB #VALUE! OUTB 395
OUT_TX_BYTE48
QB #VALUE! INB 403 IB #VALUE! OUTB 403

Author : John Gu Profinet Revision -

Approved : Page 5/21
 GAUGE I/O DIAGRAM 6037404679

Virtual Input / Output

Internal virtual signals not related to external device exchanges.

GAUGE DESCRIPTION GAUGE DESCRIPTION

INITAIL ZERO
Virtual IN 1025 Virtual OUT 1025

Virtual IN 1026 Virtual OUT 1026

Virtual IN 1027 Virtual OUT 1027

Virtual IN 1028 Virtual OUT 1028

Virtual IN 1029 Virtual OUT 1029

Virtual IN 1030 Virtual OUT 1030

Virtual IN 1031 Virtual OUT 1031

Virtual IN 1032 Virtual OUT 1032

Virtual IN 1033 Virtual OUT 1033

Virtual IN 1034 Virtual OUT 1034

Virtual IN 1035 Virtual OUT 1035

Virtual IN 1036 Virtual OUT 1036

Virtual IN 1037 Virtual OUT 1037

Virtual IN 1038 Virtual OUT 1038

Virtual IN 1039 Virtual OUT 1039

Virtual IN 1040 Virtual OUT 1040

Author : John Gu Virtual IO Revision -

Approved : Page 6/21
 GAUGE I/O DIAGRAM 6037404679

Part types list

Nr. Name Description
1 D22 Production cycle/Part repeat

11 Mean Master Calibration/Sensitivity/Mater repeat

Stations list
Nr. Name Step Description
1 Measuring Station 1 Static

Cycles list
Cycle Workpiece Type Note
Calibration Master 11 Upon operator's request
Sensitiity Calibration Master 11 Upon operator's request
Repeatability on master Master 11 Upon operator's request
Repeatability on part Sample part 1 Upon operator's request
Production cycle Production parts 1 Upon operator's request

Author : John Gu Catalogue Revision -

Approved : Page 7/21
 GAUGE I/O DIAGRAM 6037404679

CALIBRATION Launched upon operator request or E9066 request signals (Gauge

zeroed and calibration request).
校准循环
CALIBRATION=1
START
â
All transducers at home, begin to release transducers only after this step is
TRANSDUCER OUTSIDE TEST
finished. If the test fails the cycle must be aborted.
â
Transducers can be moved on the part.
LOAD MEAN MASTER
Set null PartID.
â
Instant probe reading.
MEASURE STEP 1

â
CYCLE END

â
END

Launched upon operator's request.

REPEATABILITY ON MASTER Allowed only if related type is zeroed.
标准件重复性循环 During repeatability cycle do not consider calibration requests.

CALIBRATION=0
START
â
All transducers at home, begin to release transducers only after this step is
TRANSDUCER OUTSIDE TEST
finished. If the test fails the cycle must be aborted.
â
Transducers can be moved on the part.
LOAD MEAN MASTERT
Set null PartID.
â
Instant probe reading.
MEASURE STEP 1

â
CYCLE END

â
Perform always this command in this cycle type.
STATISTIC ELABORATION

â
END

Author : John Gu Cycles Revision -

Approved : Page 8/21
GAUGE I/O DIAGRAM 6037404679

Allowed only if related type is zeroed.

PRODUCTION CYCLE Cycle not allowd if the signal GAUGE CAPABILITY ACTIVE is hight (all
生产循环 traceability data would be lost).

START
â
All transducers at home, begin to release transducers only after this step is
TRANSDUCER OUTSIDE TEST
finished. If the test fails the cycle must be aborted.
â
Transducers can be moved on the part.
LOAD PART

â
Instant probe reading.
MEASURE STEP 1

â
â
CYCLE END

â
Perform always this command in this cycle type.
STATISTIC ELABORATION

â
SEND MARKING DATA

â
END

Launched upon operator's request.

REPEATABILITY ON PART Allowed only if related type is zeroed.
工件重复性循环 During repeatability cycle do not consider calibration requests.

START
â
All transducers at home, begin to release transducers only after this step is
TRANSDUCER OUTSIDE TEST
finished. If the test fails the cycle must be aborted.
â
Transducers can be moved on the part.
LOAD PART
Set null PartID.
â
Instant probe reading.
MEASURE STEP 1

â
CYCLE END

â
STATISTIC ELABORATION
If the signal <GAUGE CAPABILITY ACTIVE> is low jump this command.

â
END

Author : John Gu Cycles Revision -

Approved : Page 9/21
 6037404679

Part Serial Code (PLC send to E9066)

Example: Value =
ASCII
Block Byte
code Data Format "123ABC456D…."
Hex Ascii
high 3
1 1st character 1
low 1
high 3
2 2nd character 2
low 2
high 3
3 low
3rd character
3
3
high 4
4 low
4th character
1
A
high 4
5 low
5th character
2
B
high 4
6 low
6th character
3
C
high 3
7 low
7th character
4
4
high 3
8 low
8th character
5
5
1 high Serial Code 3
9 low
9th character
6
6

high 4
10 10th character D
low 4
high 4
11 low
11th character
5
E
high 4
12 low
12th character
6
F
high 3
13 low
13th character
7
7
high
14 low
14th character

high
… low
15th - 31th character

high
32 low
32th character

Author : John Gu Revision -

Approved : Page 10/21
 6037404679

Measure Value, Status and Class ( E9066 send to PLC )

Block Byte fcData Data Format Example:

Value="8.0285" /Class=2

IB1003
IB1004 Float M1 value
IB1005 %fm PLC %REAL 8.0285
1 IB1006
IB1007 Word M1 Status Good
IB1008 %w PLC %Int 16#0200
IB1009 Spare 0
IB1010
IB1011 Float M2 value
%fm PLC %REAL 8.0285
IB1012
2 IB1013
IB1014 Word M2 Status Good
IB1015 %w PLC %Int 16#0201
IB1016 Spare 0
IB1017
IB1018 Float M3 value
IB1019 %fm PLC %REAL 8.0285
3 IB1020
IB1021 Word M3 Status Good
IB1022 %w PLC %Int 16#0202
IB1023 Spare 0
IB1024
IB1025 Float M4 value
IB1026 %fm PLC %REAL 8.0285
4 IB1027
IB1028 Word M4 Status Good
IB1029 %w PLC %Int 16#0203

IB1030 Spare 0
IB1031
IB1032 Float M5 value
IB1033 %fm PLC %REAL 8.0285
5 IB1034
IB1035 Word M5 Status Good
IB1036 %w PLC %Int 16#0204
IB1037 Spare 0
IB1038
IB1039 Float M6 value
IB1040 %fm PLC %REAL 8.0285
6 IB1041
IB1042 Word M6 Status Good
IB1043 %w PLC %Int 16#0205
IB1044 Spare 0
IB1045
IB1046 Float M7 value
IB1047 %fm PLC %REAL 8.0285
7 IB1048
IB1049 Word M7 Status Good
IB1050 %w PLC %Int 16#0206
IB1051 Spare 0
IB1052
IB1053 Float M8 value
IB1054 %fm PLC %REAL 8.0285
8 IB1055
IB1056 Word M8 Status Good
IB1057 %w PLC %Int 16#0207
IB1058 Spare 0

Author : John Gu Revision -

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 6037404679
IB1059
IB1060 Float M9 value
IB1061 %fm PLC %REAL 8.0285
IB1062
9 IB1063 Word M9 Status Good
IB1064 %w PLC %Int 16#0208
IB1065 Word M9 Class 16#0200
IB1066 %w PLC %Int
IB1067
IB1068 Float M10 value
IB1069 %fm PLC %REAL 8.0285
IB1070
10 IB1071 Word M10 Status Good
IB1072 %w PLC %Int 16#0209
IB1073 Word M10 Class 16#0200
IB1074 %w PLC %Int

NumberNotation(MStatus(), %w) Status Table

PLC received
Int Value Nmae Meaning E9066 Send
HEX
1 msExclude Measuremnt excluded 01h 00h 16#0100
2 msGood Measurement good 02h 00h 16#0200
3 msAppr1For measurement approch 1 forward 03h 00h 16#0300
4 msAppr1Back measurement approch 1 backward 04h 00h 16#0400
5 msAppr2For measurement approch 2 forward 05h 00h 16#0500
6 msAppr2Back measurement approch 2 backward 06h 00h 16#0600
7 msRework measurement reworkable 07h 00h 16#0700
8 msReject measurement reject 08h 00h 16#0800
9 msNotPerf measurement not perform 09h 00h 16#0900
10 msNotCalibrated measurement not claibrated 0Ah 00h 16#0A00
11 msZerGoodDBand measurement zero good d-band 0Bh 00h 16#0B00
12 msZeroGood measurement zero good 0Ch 00h 16#0C00
13 msZerNotAvail measurement zero not available 0Dh 00h 16#0D00
14 msZerErr measurement zero error 0Eh 00h 16#0E00
15 msZerRunningIN measurement zeroing running in 0Fh 00h 16#0F00
16 msZerRunningOUT measurement zeroing running out 10h 00h 16#1000
17 msNoFormula measurement no formula 11h 00h 16#1100
18 msNoElaboration measurement no elaboration 12h 00h 16#1200
19 msInvalid measurement invalid 13h 00h 16#1300

Author : John Gu Revision -

Approved : Page 12/21
 GAUGE I/O DIAGRAM 6037404679

GENERAL STATUS SIGNALS

Usually at high level (the first time it is set at the end of the gauge startup), when it is at
low level means that an error is present on E9066. On the gauge screen a message on
### #VALUE! ### #VALUE!
GAUGE EFFICIENT red foreground is displayed in order to describe the problem; to unblock the gauge the
operator must press a softkey on gauge MMI (Marposs Machine Interface).
It is suggested a polling control of this signal.

If low the gauge is not zeroed and the only operation allowed is a calibration cycle (the
### #VALUE! ### #VALUE! ACK OUTSIDE TRANSDUCERS TEST
signal includes the incremental transd. zeroing status)

Gauge capability is activated on E9066 using gauge MMI. When GC is active

(immediatly after GC START ACQUISITION command by softkey) the signal is ON.
### #VALUE! ### #VALUE!
GAUGE CAPABILITY ACTIVE During part / master repeatability cycles execute the statistical elaboration only if
the Gauge Capability mode is actived.

Request from gauge to perform a calibration cycle. It's no mandatory (part cycles can be
### #VALUE! ### #VALUE!
CALIBRATION REQUEST performed). PLC should not consider this signal during repeatability cycles)

Home position of the machine. Used to track cycles like Dryrun test (detects a new cycle
### #VALUE! ### #VALUE!
DRYRUN every new positive edge of this signal).

MODE CHANGE
### #VALUE! ### #VALUE!
AUTOMATIC
### #VALUE! ### #VALUE!
AUTOMATIC ECHO
ACK OUTSIDE TRANSDUCERS
### #VALUE! ### #VALUE!

TEST
### #VALUE! ### #VALUE!
ACK PART LOAD
### #VALUE! ### #VALUE!
ACK INSIDE TRANSDUCERS TEST
### #VALUE! ### #VALUE!
ACK START STEP
### #VALUE! ### #VALUE!
END OF ACQUISITION
### #VALUE! ### #VALUE!
ACK END OF CYCLE
### #VALUE! ### #VALUE!
END STATISTIC ELABORATION

TRANSDUCERS OUTSIDE TEST [Station #1]

STROBE OUTSIDE TRANSDUCERS
### #VALUE! ### #VALUE!

TEST
ACK OUTSIDE TRANSDUCERS
### #VALUE! ### #VALUE!

TEST
If the test fails GAUGE EFFICIENT will be reset.

TRANSDUCERS INSIDE TEST [Station #1]

STROBE INSIDE TRANSDUCERS
### #VALUE! ### #VALUE!

TEST
### #VALUE! ### #VALUE!
ACK INSIDE TRANSDUCERS TEST
If the test fails GAUGE EFFICIENT will be reset.

Author : John Gu Diagrams Revision -

Approved : Page 13/21
 GAUGE I/O DIAGRAM 6037404679

LOAD MIN MASTER <n> for CALIBRATION [Station #1]

### #VALUE! ### #VALUE!
CALIBRATION =1 Min master for calibration cycle
### #VALUE! ### #VALUE!
0 =0
### #VALUE! ### #VALUE!
0 =0
### #VALUE! ### PART TYPE CODE x 1
#VALUE!

.. … … … … =11
### #VALUE! ### PART TYPE CODE x 128
#VALUE!

### #VALUE! ### #VALUE!

STROBE PART LOAD
### #VALUE! ### #VALUE!
ACK PART LOAD
AUTOZERO=1 only for Calibration Cycle, in Master Repeat Cycle AUTOZERO=0.

LOAD MIN MASTER <n> for SENSITIVITY [Station #1]

### #VALUE! ### #VALUE!
CALIBRATION =0
### #VALUE! ### #VALUE!
0 1
=1 Min master for sensitivity cycle
### #VALUE! ### #VALUE!
0 =0
### #VALUE! ### PART TYPE CODE x 1
#VALUE!

.. … … … … =11
### #VALUE! ### PART TYPE CODE x 128
#VALUE!

### #VALUE! ### #VALUE!

STROBE PART LOAD
### #VALUE! ### #VALUE!
ACK PART LOAD
AUTOZERO=1 only for Calibration Cycle, in Master Repeat Cycle AUTOZERO=0.

LOAD MAX MASTER <n> for SENSITIVITY [Station #1]

### #VALUE! ### #VALUE!
CALIBRATION =0
### #VALUE! ### #VALUE!
0 =0
### #VALUE! ### #VALUE!
0 =1 Max master for sensitivity cycle
### #VALUE! ### 0
#VALUE!

.. … … … … =12
### #VALUE! ### PART SERIAL CODE BYTE 2
#VALUE!

### #VALUE! ### #VALUE!

STROBE PART LOAD
### #VALUE! ### #VALUE!
ACK PART LOAD
AUTOZERO=1 only for Calibration Cycle, in Master Repeat Cycle AUTOZERO=0.

LOAD PART <n> [Station #1]

### #VALUE! ### #VALUE!
CALIBRATION =0
### #VALUE! ### #VALUE!
0 =0
### #VALUE! ### #VALUE!
0 =0
### #VALUE! ### PART TYPE CODE x 1
#VALUE!

.. … … … … =1
### #VALUE! ### PART TYPE CODE x 128
#VALUE!

### #VALUE! ### PART SERIAL CODE BYTE 1

#VALUE!

.. … … … … =123ABC456D….
### #VALUE! ### PART SERIAL CODE BYTE 8
#VALUE!

### #VALUE! ### #VALUE!

STROBE PART LOAD
### #VALUE! ### #VALUE!
ACK PART LOAD
For multistations the part type code must not be longer furnished from St2 and later

Author : John Gu Diagrams Revision -

Approved : Page 14/21
 GAUGE I/O DIAGRAM 6037404679

MEASURE STEP <n> [Station #1]

### #VALUE! ### MEASURE STEP CODE x 1
#VALUE!

.. … … … … =1,2,3,4
### #VALUE! ### MEASURE STEP CODE x 128
#VALUE!

### #VALUE! ### #VALUE!

STROBE START STEP
### #VALUE! ### #VALUE!
ACK START STEP
### #VALUE! ### #VALUE!
END OF ACQUISITION
### #VALUE! ### #VALUE!
GOOD PART
### #VALUE! ### #VALUE!
REWORK PART
### #VALUE! ### #VALUE!
REJECT PART
### #VALUE! ### #VALUE!
INVALID PART
On the pos. edge of "END OF ACQUISITION" stop rotation and home transducers.
Notes :
1) For steps based on a synchronism by encoder or an external sensor show the acquisition timeout
2) Timeout = Acq. Time * 3 (sec.) ; the default is 30 sec. (Acq. Time = 10 sec.)

CYCLE END [Station #1]

### #VALUE! ### #VALUE!
STROBE END OF CYCLE
### #VALUE! ### #VALUE!
ACK END OF CYCLE
### #VALUE! ### #VALUE!
GOOD PART
### #VALUE! ### #VALUE!
REWORK PART
### #VALUE! ### #VALUE!
REJECT PART
### #VALUE! ### #VALUE!
INVALID PART
### #VALUE! ### #VALUE!
OUT_TX_BYTE1
### #VALUE! ### #VALUE!
…
### #VALUE! ### #VALUE!
OUT_TX_BYTE32

STATISTIC ELABORATION [Station #1]

STROBE STATISTIC
### #VALUE! ### #VALUE!

ELABORATION
### #VALUE! ### #VALUE!
END STATISTIC ELABORATION
Includes all post-elaboration fuctions such as counters, statistic, feedback, data transfer etc.

Author : John Gu Diagrams Revision -

Approved : Page 15/21
 GAUGE I/O DIAGRAM 6037404679

Byte 5000
Integer
Long
5000
5000
FCV - Flow Control Variables
Single 5000 Internal shared variables layout and use
String 100x80

Type Id Function Description Written by Read by

String 1 Stat. / Dtransf. Storage string for Part Serial Code from PLC fcData fcData
Long 100 Fatal Errors Special fatal error generated by Measurement Measurement fcData
Elaboration (i.e. instant probe zeroing). fcData Elaboration
writes the number +200 into the fcv variable
ErrorActive so that the error is managed by the
Flow Control.

Author : John Gu FCV map Revision -

Approved : Page 16/21
 GAUGE I/O DIAGRAM 6037404679

General
The E9066's I/O signals are divided into 3 macro groups :
1 - of mode
2 - of status
3 - strobe / acknowledge
To the first group belong the signals that modify the E9066's state of operation, typically AUTOMATIC / MANUAL.

To the second group belong all those "level" signals that, if they are inputs, enable a particular condition (e.g. CALIBRATION, etc.),
while if outputs outgoing information relating to the E9066 current status (e.g. GAUGE ZEROED) or to the just performed activity
(eg. PART STATUS at the end of cycle). If they are associated to a "strobe / acknowledge" command, the input signals must be
supplied BEFORE the command strobe, while the output signals must be read on the positive edge of the acknowledge or in any
case after this event.

Finally the "strobe / acknowledge" signals are all the commands that the control logic (PLC) can supply to the gauge. These are
pairs of signals (one Input and one Output) which are enabled only with the gauge in AUTOMATIC mode (except for a few
exceptions like PART LOAD).
In the couple of signals the default is that the input is at "0" while the output is at "1" level.
When the strobe is supplied to the E9066 the related output is set to "0" (it indicates that the E9066 has recognized the
command) and remains to this level until the strobe is reset again to "0".
With the strobe to "0", at the end of the command execution the acknowledge is returned to "1 level. If instead the input signal
remains at "0", even when the command is finished the acknowledge signal remains to low level.
Name Type Location Description
0 Gauge in Manual mode
1 Gauge in Automatic mode
AUTOMATIC INPUT / MODE CENTRAL
The current E9066's status is made available to the external devices by the
AUTOMATIC ECHO output signal.

Trigger for the DryRun test, to track the cycle duration and cadence of a
DRYRUN INPUT / - CENTRAL
machine. The cycle is timed as the interval between two consecutive positive
TRIGGER edges ; the positive edge should be related to something that happens only
once in a cycle (home position, elevator up, etc).

Signal to check the efficiency of the E9066 ; the default is at "1" level, if at "0"
GAUGE OUTPUT / STATUS CENTRAL level means that an error is present. The PLC has to execute a polling control
EFFICIENT of this signal.

Signal to check the Gauge Capability status (Active / Inactive) of the E9066 ;
GAUGE the Gauge Capability is activated using the E9066's HMI. When GC is active
(immediately after GC START ACQUISITION command by softkey) the signal
CAPABILITY OUTPUT / STATUS CENTRAL
is at "1" level. The PLC has to check this signal during Repeatability cycles in
ACTIVE order to execute or not the STATISTIC ELABORATION command (execute
only if Gauge Capability is active).

Request from gauge to perform a Calibration cycle. It's no mandatory (part

CALIBRATION OUTPUT / STATUS CENTRAL cycles can be performed). PLC should not consider this signal during
REQUEST Repeatability cycles.

[Internal name = OUT_E9066_ZEROED] Signal to check the zeroing status of

the E9066 ; if at "0" level the gauge is not zeroed and the only operation
allowed is a Calibration cycle (the signal includes also the calibration status of
GAUGE OUTPUT / STATUS CENTRAL the incremental transducers listed in FcConfig > Central > Miscellaneus >
ZEROED TR_INCREMENTAL_LIST). The signal can be splitted in presence of more
than one type with parts control in lots. Its refresh is done at the end of
Calibration / Sensitivity Adjustment cycles and at TP100 ZEROING command.

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 GAUGE I/O DIAGRAM 6037404679

The purpose of this test is to verify the functionality of the transducers,

preventing the E9066 to classify good a reject part. When a transducer stops
working it locks into a valid or invalid value : the first condition is detected by
OUTSIDE the Outside Transducers Test, the second directly by measurement results. If
the application is a multi-station there are two possibilities: synchronous
TRANSDUCERS STROBE / ACK STATION
cycles (e.g. M128) or asynchronous cycles : in the first case it's enough to
TEST provide a general Outside Transducer Test to be given while shifting the parts
(all transducers are supposed to be at home); in the second case a dedicated
command must be provided for each station. This test should be provided in
each application.

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 GAUGE I/O DIAGRAM 6037404679

Name Type Location Description

[OPTIONAL] The purpose of this test is to prevent mechanical damages. It's

INSIDE to be considered as part of the machine automation and it must be requested
to control that a specific movement has been properly carried out (e.g.
TRANSDUCERS STROBE / ACK STATION
gauging station lowered) before executing a following and potentially
TEST dangerous movement (conrod clamp or shaft rotation). The result of this test
has no relation with the quality of the measurements values.

Laod a part in station in order to execute a cycle. In automatic applications the

PART LOAD STROBE / ACK STATION default is that part type loading is separated from the start cycle to save the
internal time for part creation (e.g. during part elevation).

PART TYPE INPUT / STATUS STATION

To be set BEFORE the part load strobe, sets in input (in binary code) the part
CODE program nr to be loaded in station by the E9066.

[OPTIONAL] To be set BEFORE the part load strobe, sets in input (in binary
PART ID CODE INPUT / STATUS STATION code on more bytes) the part ID code for multistations with Part Archive or for
traceability purposes.

To be set BEFORE the part load strobe, gives to the part program loaded in
CALIBRATION INPUT / STATUS STATION station by the E9066 the attribute of "MEAN master" necessary for the
Calibration cycle.

[OPTIONAL] To be set BEFORE the part load strobe, gives to the part
SENSITIVITY INPUT / STATUS STATION program loaded in station by the E9066 the attribute of "MAX master"
MAX necessary for the Sensitivity Adjustment cycle.

[OPTIONAL] To be set BEFORE the part load strobe, gives to the part
SENSITIVITY INPUT / STATUS STATION program loaded in station by the E9066 the attribute of "MIN master"
MIN necessary for the Sensitivity Adjustment cycle.

[OPTIONAL] To be set BEFORE the part load strobe, sets in input (in binary
MASTER INPUT / STATUS STATION code) the master duplicate nr. for Calibration / Sensitivity cycles; for the same
INSTANCE calibration session (MEAN / MAX / MIN) the same instance nr. must be used.

Starts a step that includes the transducers acquisition and the measurements
START STEP STROBE / ACK STATION elaboration. The step can be of type PRODUCTION / CALIBRATION /
REPEATABILITY with or without Gage Capability.

MEASURE INPUT / STATUS STATION

To be set BEFORE the strart step strobe, sets in input (in binary code) the
STEP CODE step nr to be executed by the E9066.

[OPTIONAL] Signal to check the end of transducers acquisition, it is used to

END OF OUTPUT / STATUS STATION
speed up the cycle time. The PLC can remove the part/master from the meas.
ACQUISITION station when this signal changes from "0" to "1" level without waiting for the
end of step.

Starts the end of cycle operations at the end of the steps sequence. Usually
the END OF CYCLE includes only the part status definition (LEVEL 1) while
statistic elaboration, counters, etc. are associated to another command
(LEVEL 2). In this way the LEVEL 1 command has to be given for all cycles
END OF CYCLE STROBE / ACK STATION
(Production, Calibration Repeatability), while the LEVEL 2 is only for
Production and Gauge Capability cycles. If the PLC feature "Repeat cycle on
a scrap status" is enabled the END OF CYCLE command must be given only
once at the end of the repeated steps sequence.

It is one of the status signals at end of cycle. While the other part status
(GOOD, REJECT, REWORK) are allowed, the INVALID status means that
INVALID PART OUTPUT / STATUS STATION there is a serious problem, like a transducer in overrange or an invalid meas.
STATUS elaboration. The suggested default strategy for the PLC is to stop the machine
at the end of cycle with an error message.

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Starts the end of cycle operations of LEVEL 2 after the execution of LEVEL 1
(part status definition). Usually includes all the remaining after cycle
STATISTIC STROBE / ACK STATION operations, such as statistic, counters, data transfer and printer. The
ELABORATION inclusion / exclusion of this command depend on the type of running cycle : it
is requested only for Production and Gauge Capability cycles.

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Name Type Location Description

[OPTIONAL / internal name = IN_ROWS_ZERO] Starts the zeroing of the
incremental transducers mounted on the TP100 equipments ; the zeroing
TP100 STROBE / ACK STATION point is on the mechanical pre-travel. The list of the incremental transducers
ZEROING and their in-range limits are programmed in FcConfig > Station > Transducer
Test.

[OPTIONAL / internal name = OUT_ROWS_ZEROED ] Signal to check the

zeroing status of all the incremental transducers connected to the E9066. It is
TP100 ZEROED OUTPUT / STATUS CENTRAL
the result of the "TP100 ZEROING" command; in addition this output is
refreshed also at the end of Calibration / Sensitivity Adjustment cycles.

[OPTIONAL / internal name = OUT_TCHECK_1] Signal to check the "AT

HOME" status of the incremental transducers mounted on TP100 equipment.
TP100 AT OUTPUT / STATUS STATION The signal at "1" level means that the transducers are at home so that
HOME equipment can be moved. The signal refresh time is 250 msec. in manual and
automatic mode, but during the meas. steps the refresh is freezed.

[OPTIONAL] Usually to be set BEFORE the part load strobe, gives the result
CAMERA READ INPUT / STATUS STATION of the DMC reading. In case of an OK result and if the DMC is marked in
OK station it is requestd also the reading quality grade.

[OPTIONAL] Usually to be set BEFORE the part load strobe, sets in input (in
CAMERA INPUT / STATUS STATION
binary code) the DMC reading grade according to international standards (i.e.
GRADE A=4, B=3, C=2, D=1, F=0). These inputs are significant only with the
"CAMERA READ OK" at "1" level.

[OPTIONAL] Usually to be set BEFORE the part load strobe, gives the result
CAMERA of the comparison between the DMC read string and the string sent to the
CONGRUENCY INPUT / STATUS STATION marker. In case of a not OK congruency the suggested default strategy for the
OK PLC is to stop the machine with an error message. This input is significant
only with the "CAMERA READ OK" at "1" level.

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