CIROS Production Advance

Festo Didactic GmbH & Co. KG

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2 Advanced

2. 1 iCIM Production Manager

2. 1. 1 Creating a new deskset in the database

With the help of database masks it is possible to extend the existing range of products by more products. Because of the countless combination possibilities of desksets, baseplates and penholders only a selection of products is in the database by default.

If for example you want to produce a deskset with a certain combination which is not available in production database you can add it yourself. However it is important that new added products match existing parts in their basic structure. It is impossible to add completely new parts but variations of baseplates and penholders are possible.

Don t forget to link the adequate construction data with the new added part so that it is displayed correctly in Production Simulation. If you add a new part for a real iCIM system the construction data is not needed.

In the following example a new deskset with part number 63061 is added. It is based upon the deskset 63060 but doesn t have a thermometer.

Creating a new deskset in the database

1. Ensure that Production Simulation has been started and the desired production line is loaded.

2. Start Production Supervision ProjectStudio and load the project with the production control of the desired production line.

3. Start production mode by clicking on the command Production in the menu Project.

4. The visualization window for process operating and display opens automatically after initialization of production mode.

5. Click on the button Database to see the tables of production database and to edit them.

6. The opening screen iCIM Production Manager of the database opens.

7. You can not modify the database unless you are logged in. So click on Login and use Instructor//didactic as account data. The user Instructor has full write access to the database.


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8. Click on the button Products to open the parts list.

9. If you want to create a new part you have 2 possibilities to that. Either you take over the data set of an existing part as template or you create a new data set and fill the input fields yourself. Since the deskset 63061 is based upon the deskset 63060 it is wise to use it as template. Select the part number 63060 in the checkbox next to Part No.

10. Click on the button Create New. A dialog window will open to ask you for a new part number. Enter 63061 as part number and confirm it with a click on OK.

11. The next dialog asks you whether the current selected data set should be used as template. Answer the question with the button Yes.

12. Another option dialog shows up which asks about construction data of the new part. There are 3 options. You can decide if an empty entry, an entry with the construction data of the template or no entry should be created. Since the new deskset differs hardly from the template you can take over the existing construction data and change them. Therefore select the middle option and click on OK.

13. Now the entries of the part 63060 are automatically applied to the part 63061 .


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14. Since the deskset 63061 is a new part it is reasonable to change the name and description. Therefore enter the Name Deskset 63061 Tested and change in the Description the word thermometer in the second brackets to empty. The description is to describe the assembly of the desket and desket 63061 has no thermometer.

15. Click on Save to save the changes in the new data set.

The data set with the attributes of the new part is now element of the production database. Next step is to adapt construction data.

Adapting construction data to a new deskset

1. Ensure that you are under Products in the database window and logged in as Instructor.

2. Click on the button CIROS Construction in the top window area to see the window for construction data. There select the part number 63061 .


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3. Below Construction Data 1 is already an entry. It is the construction data of deskset 63060. As you can see there are always 2 functions in brackets separated by a comma and brackets are separated by a semicolon. The first function in brackets defines the model on which a new model is painted and is noticeable by a prefixed GRP_ . The second function defines which new model is to be painted and is identifiable by a prefixed GP_ .

4. Search for the expression (GRP_BaseplateAluType5_Hole1,GP_Thermometer);

which paints a thermometer in the first borehole of the baseplate. However the deskset 63061 has no thermometer so delete this expression.

5. Click on Save to save the modified construction data.

Now you have created the deskset 63061 and you also have defined the necessary construction data for Production Simulation. But before the new part can be produced appropriate data for the production process has to be entered in the database.


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Adding a production process to a new deskset

1. Click in the database window on the button Production Data to see a list of production process of the parts.

2. Select 63061 below Part No.. You will get a hint that for that part number no production processes are defined. Confirm the message box.

3. In the group Resource Properties select under Resource Class the option Station FESTO Assembly since the deskset is manufactured on an assembly station. You can leave the input field Resource Name empty. With Resource Type you can choose between resource class and resource name. Always select Resource Class here, this way the part it is defined that the part can be produced on all assembly stations in general so it can be used in other projects as well. With Use Macro the macro process for the deskset can be selected. For the assembly station only AsmDeskset is available.

4. In the input field Strategy under Transport Properties select ParallelTwo. Here the transport strategy is defined. For manufacturing of the deskset the two parts baseplate and penholder are needed therefore 2 carriers have to be transported to the assembly station.

5. In the group Subparts (supplied) parts are defined which have to be supplied by stock since they are necessary for assembly. Select in the first input field the part number 46144 for the baseplate and 42122 for the penholder in the second input

field.

6. The group Subparts (local) refers to parts which are in feeders at the production stations. In this case it is the assembly station on which thermometers, hygrometers and pens are available.

Warning:

Position of the Instrument Pen is fixed which means you should only select it in the third input field or you will get an error. And the fourth input field should be empty since a baseplate has only 3 holes.

Since the deskset 63061 has nothing in the first hole don t enter anything in the first input field. However select Instrument Hygrometer in the second field and Instrument Pen in the third field.


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7. The groups CNC Programs and Quality Check are irrelevant for a deskset and can be left with the default 0 .

8. Click on the button Add to add the data set for the production process to the database.

9. If you want to do a modification later if for example you found an faulty input you can always you re changes with the button Modify. With Delete a data set can be deleted from the data base while the button Clear deletes contents of all inputs fields.

The new deskset 63061 is now in the database and can be used in process tasks. You can either manufacture it with an orders list directly or create a process plan.


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2. 1. 2 Producing new added parts in an orders list

New parts which you create in the database can only be produced in an orders list or user-defined process plans because the standard strategies always produce the same parts.

As example both new created parts the deskset 63061 and the baseplate 42145 are used here.

Producing new created parts

1. Ensure that the iCIM Production Manager has been started.

2. To manufacture new added parts create an appropriate production order. Thereto you need certain access rights. Click on Login in the database window and login with User//Festo.

3. Now open the orders list by clicking on the button Orders listed in the database window.

4. Then select below Part No. the part number 63061 for the deskset. Leave Order No. at 0 and Customer No. at 1 . For Resource

select an assembly station of your production line.

5. Add the order to the orders list with a click on the button Add.


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6. Now select for Part No. 42145 for the newly added baseplate. Leave the other entries at their defaults. However as Resource select either a Mill or a MillAnd Turn station of your production line.

7. A click on Add adds the second production order to the orders list as well.

8. Switch to the visualization window of Production Supervision and start the orders list with a click on Orders Listed.

9. The button will get a blue frame and production of the newly added parts starts.

With the orders list you can manufacture any parts in the database.


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2. 1. 3 Checking and changing quality data of baseplates

Baseplates can be tested for quality. The boreholes of the baseplate are checked. Before checking the set-points for test data have to be defined.

Set-points as well as taken test data during production are archived in the production database.

Checking and changing quality data

1. Ensure that Production Simulation has been started and the desired production line is loaded. The production line has to be reset. Therefore click in the menu Edit on the command Reset work cell.

2. Start Production Supervision and load the project with the production control of the desired production line. Then start production mode by clicking on Production in the menu Project. The visualization window will open.

3. Click on the button Database to open the database window.

4. You can not modify the database unless you are logged in. So click on Login and use User//Festo as account data.

5. Click on the button Products to open the parts list.

6. Click on the button Quality Data Settings to open the parts list with defined set-points.

7. Select any untested baseplate as part number, for example 42143 .

8. In the group Quality Settings you can find 5 entries which present the set-points. Set-Point defines the nominal dimension of the borehole. Lower Limit and Upper Limit are the respective tolerance limits. Lower Warning and Upper Warning are limits which are in tolerance but are already critical and an appropriate warning is shown.


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9. You can change the set-points as you like and save them with a click on Save.

10. A click on Default loads the default quality data.

11. You can also assign quality data to new created baseplates. Therefore select the part number of the new baseplate.

12. Click on Create New to create a data set of 0 for the set-points. Then either enter the desired set-points manually or use the button Default for default values.

13. To analyze quality data click on Products and there in the top window area on View Quality Data. The window that will open shows performed quality tests so far. With the button View all you can see quality tests of all parts. With Part No. however the quality tests of a specified part are shown.


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14. Start a quality test for the baseplate 42143. This baseplate changes to baseplate 46143 after the test. The part number only changes in the second digit. In general you can say that all baseplates whose part number starts with 42 are untested while whose with 46 are tested baseplates. To start a quality test you can start the appropriate production order. Thereto click on Orders listed in the database window.

15. Then enter 46143 in the input field Part No. Leave the other input fields at their default values and select under Resource the option Quality.

16. Add the production order to the orders list with a click on Add.

17. You can start the quality test by switching to the visualization window of Production Supervision and clicking on Orders Listed.

18. After the production order is finished you can see the quality test result under View Quality Data in the Products window.

With the settings of quality data you can purposefully produce good or bad parts if you change the tolerance limits accordingly.


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2. 2 Production Supervision

2. 2. 1 ProjectStudio and Macro Process Tasks

In Production Supervision ProjectStudio, you can program parts of the production control yourself. For example, you can create a production process of the production line. The process determines in which order the single production steps should be executed.

You create the production process in an own process plan by using predefined Macro Process Tasks. There are Macro Process Tasks available for every station. Programming is done in the 2D-View of the production line in Production Supervision. You select the desired process task. Then Production Supervision adds it to the table for process plan automatically.

Extensive descriptions of the process tasks and their parameters can be found in the online help of CIROS Production.

Hint: Before a production process can be created a production line has to be imported and the project needs to be generated.

When you load or import and generate a project in Production Supervision you can see the window ProjectStudio on the right side. At the bottom boarder of the window there are 3 tabs.

In Properties, the left tab, different properties of a station are shown. Select that tab and click on any station in the 2D model of Production Supervision. Then you can see different properties of that station.

The tab Library in the middle shows the libraries which are available in Production Supervision. However it is not important for the ProjectStudio s application.

The tab Process plan is important. Here a process plan that defines a specific production process of the production line can be created. With the macro process tasks commands can be sent to the stations or to the whole production line.

There are 3 columns in the Process plan window. The column Device shows for which station the macro process task is executed. Next to it is the column Process Task that defines which process task is executed. The third column Parameter includes the entered parameters of the macro process task.

A small example will show how a process plan can be created with macro process tasks. In the example a baseplate 42141 is taken from stock and transported to the assembly station. There it is placed in a pallet buffer and afterwards it is transported back to the stock.


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Creating a process plan with macro process tasks

The task is to create a process plan with the following production process:

The stopper at the stock is activated

The baseplate 42141 is taken from stock and moved onto the stopped carrier

The carrier with the baseplate moves to the stopper of the assembly station

At the assembly station the robot takes the pallet with the baseplate and places it on a buffer position, meanwhile the stopper at the assembly station is released

The stopper at the assembly station is activated

The robot of the assembly station moves the pallet with the baseplate 42141 onto the stopped carried

The carrier with the baseplate is then transported to the stopper of the stock

There the pallet with the baseplate 42141 is put in a free position in stock

The necessary process plan for that can be generated easily by using ProjectStudio and Macro Process Tasks. The following steps explain the creation in detail.

1. Make sure that Production Supervision ProjectStudio is started.

2. Load a project with a stock and an assembly station.

3. Ensure that the automatically generated program for the production control system is present. To do this, activate the Project index entry in the Project window. You will see that the project tree is filled with process plans, devices, drivers, etc. The production control system for the production line is therefore present.

4. Activate the tab section Process plan in the window ProjcetStudio. A window will open with an empty process plan.


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5. Highlight the Stock station. Activate the context-sensitive menu with the right mouse button. Under the entry Process task a list will be displayed of the macro process tasks of the Stock station. Above the line macro process tasks of the specific station are displayed. Below the line you see special commands for the control of the transport system. Since all stations are connected to the transport system these commands are the same for every station.

6. Stoppers of the production line usually open automatically to guarantee a continuous material flow. But in order to put parts on the transport system a stopper needs to be activated. The command REQUIRE, which you can find in the context menu Process Task of every station, calls a carrier to the specific station. Therefore click on REQUIRE in the stocks context menu.

7. In the dialog window you can define a CarrierID. You can enter here any number which will be reserved for the carrier and then no other carrier can use the same ID until it is released again. With that ID it is possible to identify certain carriers, which is important especially for parallel running processes. Since the production process of this example has no parallel processes any ID may be used. There use the default and click on OK. In the ProjectStudio window a new line is inserted which shows the process task, its parameters and you can see as well to which station the task belongs.

8. The next step is to move the baseplate 42141 on the carrier at the stopper position of the stock. Click with right mouse button on the stock station and select Process Task -> MovToTrans in the context menu. This macro process task places a part of that station on the transport system. The dialog window that appears needs the parameters PartNumber and OrderNumber. Enter the partnumber 42141 and leave the ordernumber at 0 . Confirm the dialog with OK.

9. Now the baseplate is on the transport system and can be transported to the assembly station. Thereto open the context menu of the assembly station AssemblyRV1A, or any other assembly station, and call the function Process Task -> to_AssemblyRV1A. In the dialog window enter for CarrierID the same ID as you used before for this carrier when reserving it. The command then moves the carrier with the specified ID to the assembly station and stops it.

10. Afterwards the robot should put the baseplate 42141 on a buffer position of the assembly station. For this the macro process task MovFromTrans is used which you can find in the context menu of the


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assembly station under Process Task -> MovFromTrans. For the parameter PartNumber use 42141 and leave the OrderNumber at the default of 0 . Then click on OK to confirm the dialog window.

11. The stopper at the assembly station would be still activated although it is not needed since the baseplate is on the assembly station. This could lead to significant delays in the material flow and therefore should always be avoided. The stopper is still active because the reserved carrier received the command to stop at the assembly station. If the reservation of the carrier is removed with the command RELEASE the stopper will open. Therefore click in the context menu of the assembly station on Process Task -> RELEASE to release the carrier and to ensure a continuous material flow. The parameter CarrierID should be the same ID as was reserved for that carrier.

Hint: It is recommended to always execute a RELEASE command after a MovFromTrans macro process. An activated stopper hinders the material flow and should be opened as fast as possible.

12. Now it is possible to do some applications on the assembly station. However the task is to transport the baseplate directly to the stock again. Since the reservation of the previous carrier was removed in the last step it is necessary to do a new reservation. Click with the right mouse button on the assembly station und execute the commands Process Task -> REQUIRE. Again a dialog window will open and ask for a CarrierID. You can use 1 again because the previous reservation was already released.


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13. After a carrier stops the robot places the pallet with the baseplate on it. For that, use the comman MovToTran under Process Task in the context menu of the assembly station. Use 42141 as PartNumber again since it has not changed. If a deskset is manufactured the partnumber will change and then it has to be considered.

14. Now click right on the StockSingle and use the command to_StockSingle in Process Task. Type in the ID of the reserved carrier so that it is transported to stock.

15. When the baseplate has arrived at the stock it has to be stored. The macro process task MovFromTrans, which can be found in Process Task in the context menu of the stock, stores the baseplate. Enter the partnumber 42141 and the part is stored automatically in a free storage bin of the stock.

16. Though the task is finished now it is very important to free the reserved carrier at the stock station. If that does not happen the material flow will stand still and no other production processes can be executed. Therefore click with the right mouse button on the stock station and select the command Process Task -> RELEASE. Enter the ID of the reserved carrier and it will be released.

A list of the macro process tasks should now be visible in the ProjectStudio window. It displays the production process that is asked for in the task. This process plan first has to be generated before it can be executed.

If you find an error in a line then double click on that line. A dialog window will open to this line in which you can do the necessary modifications.


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Generating and executing a macro process task

1. To use the process plan created in the ProjectStudio Window it first has to be generated. Activate setup mode by clicking on

Setup in the menu Project or on the button . Then click in the menu Extras -> ProjectStudio on Generate process plan or use the button

.

2. A dialog window will open which asks for a name for the process plan. The default is Prod_User1 which you can use. You can also use any name you want but it is reasonable to use either Prod_User1, Prod_User2 or Prod_User3 as name. User-defined process plans with one of these names can be called directly in the visualization window with the buttons User 1, User 2 and User 3. The generated process plan is saved in the Project window on the tab Project in Local Project -> Process plans -> User.

3. To start the process plan first set Production Supervision in production mode. Click therefore on Production in the menu

Project or use the button .

4. When the visualization window of Production Supervision is loaded the created process plan can be started. Just click on the button User 1 in the visualization window.

5. The process plan is executed and the button User 1 has a blue frame as long as it is active.

Hint: Consider that error handling like for the standard strategies is not working for user-defined process plans. Even if your process plan has no syntax errors logical errors still may occur. Debugging is not possible in the ProjectStudio and therefore complex process plans can not be created.


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2. 2. 2 Rebuilding the standard strategy Penholder with macro process tasks

This chapter shows how a standard strategy can be rebuild with macro process tasks easily. The standard strategy Penholder produces a penholder with part number 42104 from raw material.

Manufacturing a penholder with macro process tasks

1. Ensure that Production Supervision ProjectStudio and Production Simulation have been started.

2. Open in both programs the same production line and ensure that the project contains a CNC mill or turn machine. A transport system and a stock station are also necessary.

3. Click on the window ProjectStudio in Production Supervision on the tab Process plan to see the columns of the process plan.

4. To produce the penholder raw material has to be transported to the CNC machine. However a carrier is needed for the transport which has to be called by the stock station. Therefore click with the right mouse button on the stock station and select the command REQUIRE in Process Task.

5. Enter 1 as parameter for the CarrierID in the opened dialog window.

6. Afterwards put the penholder s raw material on the stopped carrier by clicking on Process Task -> MovToTrans in the context menu of the stock. Anschließend laden Sie den Stifthalter auf den gestoppten Grundträger, in dem Sie im Kontextmenü des Hochregallagers auf Process Task -> MovToTrans klicken. In the dialog window enter 42000 for PartNumber and leave OrderNumber at the default of 0 .

7. Now the raw material has to be transported to the CNC station therefore use the command to_Mill / to_Turn / to_MillAndTurn in the context menu of the CNC station under Process Task. The exact name depends on the CNC machine used. The dialog window then asks for a CarrierID enter the 1 since you reserved this ID before.

8. Click with the right mouse button on the CNC machine and select Process Task -> MovFromTrans and enter the part number 42000 . With the macro process task the raw material is moved

from the transport on a buffer position of the CNC station.

9. Before continuing the stopper at the CNC machine should be released to guarantee a continuous material flow. Use the command RELEASE in the context menu of the CNC machine.


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10. Now the raw material can be manufactured in the CNC machine. Click with the right mouse button on the CNC machine and select Process Task -> ProdPenholder. The function needs the parameter TargetPartNumber so enter 42104 since that penholder is to be produced.

11. After the penholder is produced it is taken back to stock but for this a carrier is necessary. With Process Task -> REQUIRE in the context menu of the CNC machine a carrier is reserved. Since the previously reserved carrier is freed again you can use 1 as ID again.

12. To place the penholder on the carrier use the macro process task MovToTrans in the context menu of the CNC machine. For part number use 42104 because the produced penholder is to be moved.

13. Click with the right mouse button on the stock station and select Process Task -> to_StockSingle. The carrier will then be moved to stock and stops there.

14. Another right click on stock and the command MovFromTrans stores the penholder in the stock. Enter 42104 as part number.

15. At last the stopped carrier at the stock station has to be released again. Else the material flow stops and other production processes can not be executed. Therefore click on RELEASE which you find in the context menu of the stock station and enter the ID 1 .

16. The process plan in the ProjectStudio window is finished and can be tested. But first it has to be generated. Activate setup mode in Production Supervision by clicking on Setup in the menu Project or

on the button .

17. Click on Generate process plan in the menu Extras -> ProjectStudio to generate the process plan. As name use either Prod_User1, Prod_User2 or Prod_User3 to be able to start the process plan in the visualization window directly. Enter Prod_User1 and confirm that an existing process plan should be replaced.

18. Start production mode of Production Supervision with the command Production in the menu Project or

use the button .

19. You can start the created process plan in the visualization window by clicking on the button User 1. If you used Prod_User2 or Prod_User3 as name then click on the appropriate button.

This example shows that standard strategies can be rebuild with macro process tasks. However the macro process tasks and the creation in the ProjectStudio have the advantage that the process now can be expanded or modified in any way.


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2. 2. 3 Working with the Tasktool (F3) in Production Supervision

With Production Supervision and Production Simulation you can simulate production lines and start production processes. For that macro process tasks are started which execute complete processes like assembling a deskset.

During a system installation or for testing purposes it would be better to control single stations of the iCIM system directly. For this Production Supervision offers the Tasktool.

With the tasktool operations of components of an iCIM system can be started directly so that for example a robot program on an assembly station can be executed. But the tasktool only works if Production Supervision is in production mode.

In the following example the simulation is stopped and started again with the tasktool. Further a part from storage bin No. 1 is to be moved to storage bin No. 40.

Starting and using the tasktool


2. Open in both programs the same production line.

3. Start production mode in Production Supervision by clicking in the menu Project on the command

Production or using the button .

4. Usually then the visualization window opens and is active therefore switch back to the Production Supervision window.

5. Press the F3 key or click on Tasktool in the menu View.

6. The tasktool has a simple design. On the left you see the stations and their components in a checkbox. Depending on the selected component the contents of the list box on the right changes. In the list box all executable process tasks of the selected component are shown. If you click on one entry it is entered in the text box so that necessary parameters can be edited. With a click on Start a process task is executed.

7. If you select in the component selection a station like StockSingle you will see the stock s macro process tasks. However if you select the component StockSinglePLC of the stock then you will see process tasks which control the PLC directly.


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8. Select the component TransportPLC. In the list box click on the entry StopSimulation( ). The process task is inserted in the text box above the list box. Since the process task does not need any parameters it can be started directly with the Start button. Switch to th Production Simulation window the transport system should be halted now.

9. To restart the simulation of the transport system select the entry RunSimulation( ) in the list box and execute the process task with a click on Start.

10. Before you can move a part in stock from one storage bin to another one the destined storage bin has to be empty. Therefore start the database window by clicking on Database in the visualization window of Production Supervision.

11. In the database window click on Login and use User/Festo for login data. Then click on Stock Contents. Select storage bin No. 40 and click on Reset to delete its content.

12. Switch back to the Production Supervision window with the open tasktool.

13. Select the component StockSinglePLC. This component controls the stock s PLC. The Entry Mov([Par1, Par2, ...]) in the list box is the process task for stock handling. The process task awaits 2 parameters. The first parameter is the source position and the second one is the target position. Therefore enter Mov(1,40) in the text box and start the process task with Start.

14. Switch to the Production Simulation window to watch the movement of the stock handling.

Hint: The process tasks in the tasktool won t modify the database. That means that the stock contents won t change. This can lead to errors if then standard strategies or macro process tasks are started in the visualization window.


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The most important process tasks of the components can be found on the online assistant of CIROS Production. You can start it in the start menu under Programs -> CIROS Production -> CIROS Production

Assistant.

Click on Contents in the online assistant. There you can see an entry to every station and if you expand the entry by clicking on the + character you will find an entry Process tasks for most stations. There you can find a description of the parameters for the process tasks.


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2. 2. 4 Starting robot programs with ExecProg

Executing robot programs in Production Supervision directly is especially interesting for real iCIM systems. This way you can start self programmed robot programs in Production Supervision to test them or to integrate in process plans.

Though the usage of ExecProg in Production Simulation is identical to a real iCIM system but currently it is not possible to implement user-defined robot programs in the models of Production Simulation. Therefore only the available robot programs can be started.

ExecProg can be executed in the tasktool or in a process plan. The default programs of the robot can be found in the online assistant.

The following example demonstrates the call of ExecProg in the tasktool. Thereto a thermometer of the assembly station is moved to the test position of the vision system.

Starting robot programs with the tasktool


2. Open in both programs the same production line. Ensure that the production line contains an assembly station.

3. Start production mode in Production Supervision by clicking in the menu Project on

the command Production or on the button .

4. Usually then the visualization window opens and is active therefore switch back to the Production Supervision window.

5. Press the F3 key or click on Tasktool in the menu View.

6. Select as component the robot of the assembly station. The robot is indicated by an additional Robot to the station s name. In the example project an assembly station with a RV3SV robot is used therefore is the component to choose AssemblyRV3SBRobot.


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7. In the list box of the tasktool the different process tasks of the robot are displayed. Highlight the entry ExecProg([Par1, Par2, ...]), which is then displayed in the text box. ExecProg needs several parameters. The first one should be a string and defines the robot program to be executed while the following parameters are the parameters for the robot program.

8. If you look up the robot programs for the assembly station in the online assistant you will find out that the program MINST is used for moving instruments. Three parameters are necessary for the program. The first one is the source position, the second one the target position and the third one is the rotational angle the robot should execute. Possible values for the parameters are written in the online assistant.

9. The thermometer is in the first feeder that is position 1 in the robot program. The testing position ist position 5 and the rotational angle is not relevant so 0 can be used. Therefore enter in the text box the following process task:

ExecProg("MINST",1,5,0)

Then startthe process by clicking on Start and watch the robot in the Production Simulation window.

10. In the Production Supervision message window a message is displayed that the process task has been started. When the process is finished another message appears as well as a return value.

The usage of ExecProg with a real iCIM system is more flexible since test objects can be easily placed on the

robot station. A possible application of ExecProg with Production Simulation would be to replace a macro process task like the deskset assembly with direct calls of the robot programs.


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2. 2. 5 Programming in process plan language

Macro process tasks are saved in a process plan. In a process plan production process can be programmed. For this, the process plan language of CIROS Control is used.

The process plan language is a high level language but differs from other popular programming languages. It is an interpreter language and line oriented. Every line has a definite count of columns.

The columns in a process plan

The following list explains the names of the columns of a process plan. Furthermore the use is mentioned.

Line: A process plan is line oriented thereby every line has to be labeled explicitly. Usually the lines are numbered but words are also possible. Particular words can indicate a certain function or can be used as legible jump label. The line label, whether numerical or as text, must not be missing else it is considered a syntax error.

Condition: In this column a number, a text in quotation marks or a numerical range can be entered. For a numerical range the start and end value is separated by 2 points. With commas you can also enter a separated list of several conditions with different data types. With a condition an IF-THEN-ELSE construct can be implemented however consider that for strings there is a difference between upper and lower case.

Device: In the device column is either a component from the Production Supervision project inserted or a function of Production Supervision.

Process task: Process task starts either a process task or a process plan of the selected component. Parameters can be passed, too. Also mathematical operations or processing of variables and return values respectively is possible if Production Supervision function is defined as component.

Next line: At the end of every line you can define which line should be executed next. If that column is empty the following line is execute automatically. You can enter here any label which is defined in the column Line of the process plan. Thus it is possible to define jumps in the process plan. In the last line of the process plan an END hast to be in this column. It indicates the end of the process plan and if it is missing a syntax error will occur.


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Functions in process plan language

The Production Supervision functions that can be use under Component in the process plant always start with a point. You can find information to all functions in the online help of Production Supervision. Thereto click on the question mark ? in the menu and click on Index. Select the tab Contents in the online help and open the directory User manual. There you see the entry Functions in process plans which contains a list of Production Supervision functions.

Variables in process plan language

Variables in process plan are declared with a prefixed %

character. A data type is not necessary since Production Supervision uses the Variant Type. This type can take both numerical values and strings. Strings in process plan language are indicated with quotation marks at the beginning and end. For more details about Variables open the Production Supervision online help and navigate in Contents to User manual -> Introduction -> Process plans -> Variables in process plans.

Comments in process plan language

If you enter a semicolon ; in the column Line so Production Supervision will see the line as a comment line and ignores it for the production process. You can enter any text as comment.

The following example shows how to create and edit a new process plan in Production Supervision. With a process task a part in the stock is moved from storage bin No. 1 to No. 40.


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Creating and editing a process plan


2. Open in both programs the same production line and ensure that the production line et least contains a transport system and a stock station.

3. Activate setup mode in Production Supervision. Thereto click on Setup in the menu Project or

on the button . If the button is pressed or there is a tick on the menu entry then setup mode is already active.

4. Now create a new empty process plan by clicking on Process plan in the menu File -> New.

5. Navigate to the directory Local Project on the tab Project of the Project window.

6. There you should see the entry Processplan1 which is the new process plan.

7. Click on the process plan to highlight it blue. With the key F2 you can change the name of the process plan. Another way to rename the process plan is just another left click on it while it is highlighted.

8. Open the properties of the process plan with a right mouse button click on the process plan and a left click on Properties afterwards.

9. In the properties dialog you set or change different settings for the process plan. You can also change its name here. The other options can be looked up in the online help by clicking on the Help button of the properties dialog. An important setting is the Process plan class which defines the class of the process plan. The class is then visible as subfolder in the Process plans directory. Use Processplan_01 as name and User as process plan class to move the new process plan in the directory for user-defined process plans.

10. After you have created a process plan and changed its properties you can edit it and define process task. Double click on the process plan to open it.


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11. The process plan is empty and editing is only possible if setup mode is active. If the button

is pressed setup mode is active.

12. Now you can fill the first line directly with the Mov command of the stock.

13. Therefore enter 100 as line number and leave the column Condition empty.

14. As for component enter the station name with an additional PLC , for a simple stock it would be StockSinglePLC.

15. In the column Process task enter the movement command for the stock. The command needs 2 parameters, first the source position and then the target position. The source position is 1 while the target position is 40 . Therefore enter Mov(1,40) as process task.

16. Under Next line insert an END which ends the process plan.

17. If you want to change an existing process plan then often you need to add a blank line. With a right click in the line before you want to add a new line and the option Insert empty line a blank line is added. Alternatively you can use the key combination Ctrl + Enter.

18. Now save the process plan by clicking on Save all in the

menu File or on the button .

19. Now if you look in the project window next to your process plan you will see its state. Currently it should be edited therefore close the process plan.

20. After the process plan is closed it can be checked for syntax errors. Click right on the process plan in the project window and execute the command Check. In the message window a hint is displayed that the process plan has no errors and no warning.


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21. To start the process plan Production Supervision hast to be in production mode. Click on Production in the menu Project or use

the button .

22. Before you can move a part in stock from one storage bin to another one the destined storage bin has to be empty. Therefore start the database window by clicking on Database in the visualization window of Production Supervision.

23. In the database window click on Login and use User/Festo for login data. Then click on Stock Contents. Select storage bin No. 40 and click on Reset to delete its content.

24. Now you can start the process plan. Switch to Production Supervision and right click on the process plan. The command Start should be available now. Execute it and watch in Production Simulation how your created process plan is executed.


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2. 2. 6 Replacing a macro process task with ExecProg in a process plan

With ExecProg robot programs can be executed directly. To deepen work with ExecProg, this chapter shows how to replace the macro process ProdPenholder with single process tasks in the user-defined process plan. The procedure is eased with the tasktool.

First it should be analyzed which steps the macro process contains. Definitions and parameters of the process task can be found in the CIROS Production Online Assistant. In the contents of the Online Assistant you can find a list of different stations and in the directory of each station is an entry called Process tasks and their parameters. These process tasks can be called in a process plan directly with ExecProg.

Replacing a macro process task with single process tasks

Single steps of the macro process ProdPenholder

Raw material is loaded in the CNC machine

Production in the CNC machine is started

The finished penholder is moved back on a buffer position

The following shows how these steps can be realized with ExecProg.


21. Open in both programs the same production line and ensure that it contains a milling CNC machine, a Station Mill55 is recommended. Also a transport system and a stock station are required.

22. Open in the Project window the user-defined process plan for producing a penholder which was created with macro process tasks. If there is no such process plan create a new one. See the appropriate chapter for that.


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23. Scroll down in the process plan until you find the line in which the process task ProdPenholder is used.

24. Highlight that line by clicking on the grey column on the left. Delete the highlighted line with the Del key or right click on the line and use the command Delete.

25. Then insert an empty line with the key combination Ctrl + Return or right click on the line and select Insert empty line.

26. Open the tasktool with the F3 key or use the command Tasktool in the menu View auf.

27. Now select the component Mill55Robot, if there is a Mill55 station in the production line. Is a different mill station connected so select its appropriate robot station.

28. Select ExecProg in the list box which is move to the input field. Delete the contents inside the brackets.

29. Inside the brackets ExecProg awaits 4 parameters. First parameter is the robot program which should be executed. The following 3 parameters are then transmitted to the robot program.


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30. For loading the CNC machine with raw material, the robot program LMILL exists which needs 2 parameters. First parameter is the source position of the raw material and second parameters tells what kind of part it is. Enter the following in the input field of the tasktool:

ExecProg( LMILL ,1,2)

The command calls the program LMILL and indicates that raw material is on buffer position 1 . The second parameter indicates that a penholder is loaded.

31. Click left on the column Line in the empty line of the process plan. Enter a line number which is higher by 1 than the previous line. Then click on Insert to insert the process task in the empty line. The columns Device and Process Task are filled with information from the tasktool.

32. Click in the next line and add a new line again. Enter a line number higher by 1 as well.

33. Since the raw material is now in the CNC machine the appropriate CNC program has to be started. Select the component Mill55CNC if there is a different mill station in the production line then select its appropriate CNC component.

34. Choose ExecProg in the list box and enter the following in the input field of the task tool:

ExecProg(104)

The CNC machine only needs one parameter and that is what CNC program should be started. More is not necessary. The CNC program is determined by the last 3 digits of the part number. However it is important that the target part number is used since the appropriate part is to be produced.

35. One click on Insert takes over the process task from tasktool to the process plan.


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36. The penholder is now manufactured. The next step is to move it back on the pallet. For this the robot program ULMILL is used. It needs 2 parameters like LMILL and the first one indicates the target buffer position while the second one tells if a penholder or baseplate is used. Therefore click in the next line and add a new line again. Enter a line number higher by 1 as well.

37. Select component Mill55Robot in the tasktool again and choose ExecProg in the list box. Enter then in the input field the following process task:

ExecProg( ULMILL ,1,2)

The command calls the program ULMILL and indicates that the produced penholder is to be put on buffer position 1 . The second parameter indicates that a penholder is used.

38. Add the process task in the empty line by clicking on Insert.

39. The modification in the process plan is now finished. The three inserted process tasks replace the macro process task ProdPenholder. Save the process plan with the

command Save all in th menu File or use the button .

40. Close the process plan. To see if the user-defined process plan has no syntax errors right click on it in the project window and select the option Check. The message window shows occurred errors or warning. A double click on an error or warning opens the process plan automatically and focuses the problematic line.


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41. Before the process plan can be executed Production Supervision has to be in production mode. Click therefore on Production in the

menu Project or use the button .

42. As soon as the window for starting production is closed automatically switch to Production Supervision. Right click on the process plan and the command Start executes it.

43. Observe the process in Production Simulation and in the visualization window.

The example is easy since buffer reservations at the station are ignored. This also has the disadvantage that always only one penholder can be produced at the same time and raw material has to be on buffer position 1 . Still the example shows that you can replace macro process tasks with single process tasks. Of course it is also possible to create new process plans with the tasktool. Macro process task can also be inserted with the tasktool if a station like Mill55 is used as component.


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2. 2. 7 Debugging a process plan

Debugging is important for programming. While syntax errors can be found by the interpreter a debugger may help to find errors in the production process.

In Production Supervision, you can set breakpoints in process plans. The production process will then stop and can be continued step-by-step or normally. Furthermore local or global variables and system variables can be read and analyzed.

In the online help of Production Supervision you can find in the contents under User manual -> menu commands -> commands of the menu Debug details about all debug function in Production Supervision. Below the debugging functions for usual use are introduced.

Setting or removing breakpoints in a process plan

1. Ensure that Production Supervision ProjectStudio has been started.

2. Open a project with a user-defined process plan.

3. Open in the Project window the user-defined process plan which was created with macro process tasks or the tasktool. If there is no user-defined process plan create a new one.

4. Highlight any code line in the process plan and press the key F9 or click on Toggle breakpoint in the menu Debug. In the grey column on the left of the process plan a red point appears and the whole line is highlighted in red. This means the production process will stop in that line. Consider that breakpoints can t be set in a comment line.

5. To remove a breakpoint, select the red line with the breakpoint. Then press again F9 or the command Toggle breakpoint in the Debug menu. The red point at the beginning of the line disappears and the line isn t highlighted in red anymore. The production process won t stop in that line.


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Continuing a process plan step-by-step or normally

1. Ensure that Production Supervision ProjectStudio has been started.

2. Open a project with a user-defined process plan.

3. Open in the Project window the user-defined process plan which was created with macro process tasks or the tasktool. If there is no user-defined process plan create a new one.

4. Highlight any code line in the process plan and set a breakpoint by pressing the key F9 or clicking on Toggle breakpoint in the menu Debug.

5. Close the process plan and start production mode in Production Supervision. Click on Production in the

menu Project or click on the button .

6. As soon as the visualization window is loaded switch back to Production Supervision and wait until the window for starting production mode closes automatically.

7. Start the process plan with the breakpoint and scroll down in the project window to the directory Processes. In the subfolder User you will find the executed process plan and its state. The state will be Active at first until the line with the breakpoint is reached. Open the process plan and a green highlighting will show the currently executed line. When the line with the breakpoint is reached the highlighting changes to yellow and the state of the process plan will be Stopped.

8. To continue the production process step-by-step wise press the key F8 or click on Next step in the menu Debug. The yellow highlighted line in process plan is processed and the following line is highlighted in yellow.


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9. Now you can continue the process plan step-by-step or until the next breakpoint and the end of the process plan respectively. For that use the command Start/Continue in the menu Debug or press the key F5.

In the directory Processes of the Project window you find in the appropriate subfolder all currently executed process plans. A double click on process plan opens it and a green highlighting shows which line is currently processed. A yellow highlighting indicates that the process plan is stopped since a breakpoint has been set. You can also set breakpoints in running process plans however breakpoints that are set before the currently executed line won t be considered.

Besides stopping and starting of process tasks it is also necessary to watch values of local defined variables in process plans.

Observing and changing values of variables in a process plan

1. Ensure that Production Supervision ProjectStudio has been started and is running in production mode.

2. Start a user-defined process plan with a definition or use of variables however set a breakpoint first.

3. Scroll in the Project window to the directory Processes and open it. Search the user-defined process plan in the appropriate subfolder. Click on the + character next to the process plan to see more subfolders.

4. One of the subfolders is called Local process variables. In that folder is a list of all current local variables in use and their values in the column state.

5. In the subfolder Local system variables you can see the state of different system variables. Information on the system variables can be found in the online help of Production Supervision under User manual -> System variables.

6. Variables are labeled with a V. A double click on a variable opens a small dialog in which the variable s value can be changed.

7. Now you can continue the process plan step-by-step wise or normally and observe how variable values are changed.


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2. 3 Exercises

2. 3. 1 Exercise 2.1: Creating a new deskset and manufacturing it

Task Create a new deskset.

The new deskset should have the partnumber 100000 . It contains a baseplate type 1 with part number 42140 and a brass penholder type 1 with part number 42120 .

Manufacture the new deskset.


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Hint Under Products

in the database you can create new products and in Production Data necessary information for production are saved.

The deskset 50000 is similar to the new deskset 100000. The difference is that an aluminium penholder instead of a brass one is used. Therefore it is recommended to use deskset 50000 as template.

Also construction data for the new deskset can be used from deskset 50000. Just edit the construction data for the new deskset.

With orders listed you can produce any part in the database. So create a production order with part number 100000 to create the new deskset.


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2. 3. 2 Exercise 2.3: Producing a baseplate with macro process tasks

Task

Hint

Produce the baseplate 42143 .

For this create a process plan which manufactures the baseplate 42143 with the help of macro process tasks.

Afterwards start the process plan to produce the baseplate.

In the context menu of a station in Production Supervision

you can select different macro process task under Process Task.

With the command REQUIRE a carrier stops at the calling station. However consider that a RELEASE always has to be called before. It is recommended to use the RELEASE command after a pallet was taken from transport system and the stopped carrier is no longer needed. So in general after the macro process task MovFromTrans.


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2. 3. 3 Exercise 2.4: Replacing the macro ProdBaseplate with ExecProg tasks

Task

Hint

Use a process plan with the macro process task ProdBaseplate and replace it with single process tasks. Use ExecProg for that.

First think about the steps done in the macro process ProdBaseplate .

Use the tasktool to insert ExecProg process tasks easily in a process plan.

Ignore buffer reservations for now and work only with pallet position 1 on the CNC station.


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3 Appendix

3. 1 Solutions

3. 1. 1 Solution 1.1: Modeling a production line in CIROS Production Simulation

Note

Attention

Solution

Start CIROS Production Simulation.

Click in the File menu on the command New Production Line

and save the production line as Exercise_1_1.mod .

The system editor as well as the model libraries will open. If the model libraries window won t open, open it with Model Libraries

in the Modeling menu or by

clicking on the button .

Check if the edit mode is active. There should be a tick next to the entry Edit Mode in the Modeling menu respectively the button

is pressed. If that isn t the case activate the edit mode.

Ensure also that the view is set to Top View in the edit mode. To change the view first deactivate the edit mode, then use either the right mouse button on the work space or the commands in the menu View -> Standard Views to change to top view. Activate the edit mode again since it is deactivated when changing the view.

This solution may differ from your solution. Especially on creation of a production line the positions of the stations can be different. But if your solution satisfy the task sufficiently it is correct too. Here you see just one correct solution.

Production Simulation must not be closed under any circumstances as long as Production Supervision is running!

The same model as used in Production Supervision must be loaded in Production Simulation!

Changes on the production line in Production Simulation should never be made during production mode in Production Supervision. Else severe errors will occur!

On closing of Production Simulation you will be asked whether to save the production line. It is recommended to decline this since at this time there are parts loaded in the warehouse. This would be fatal for future simulations.


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Scroll down in the model libraries window to the Transport System 6 model. Select it and add it to the system editor with the Add button or double click.

The model is displayed in green that means it is selected in the editor. As long as the model is selected you can move it as you like while holding down the left mouse button. To cancel the selection just click anywhere next to the selected model. To select it again a simple click on the model is enough. You can also delete a selected model by right clicking on it and executing the Delete command.

Add now the Station StockSingle. Search for the model in the model libraries and add it by double clicking or using the Add button.

Connect the stock with the transport system. To do this click on the stock with the left mouse button to select it and hold the mouse button down. Now move the stock that its coupling point is on the bottom left coupling point of the transport system. Release the left mouse button. If the stock aligns automatically to the transport system then the two models are connected.


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Now add a Station Assembly RV-2A to the production line. Connect it to the bottom right coupling point of the transport system while moving the assembly station with pressed left mouse button there.

Since the *-mod file is saved automatically when the XML data interchange file is created you don t need to save it explicitly. To create the XML data interchange file for Production Supervision click on Create plant

in the Extras menu or use the

button . Accept the file name and save the XML file.

The task is now solved. You can leave the edit mode and switch to the 3D view.


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3. 1. 2 Solution 1.2: Simulating the production and producing a desk set

Note

Attention

Solution

If Production Simulation isn t running start it. Load the production line Exercise_1_1.mod , by clicking on Open in the File menu and selecting the appropriate model file.

It is always wise to reset the model before simulating it. You find the appropriate option Reset Workcell in the Edit menu of Production Simulation.

Now start CIROS Production Supervision. It is important that you start the ProjectStudio therefore click on the link COSMIIR Factory

Control ProjectStudio in the start menu.

After Production Supervision has loaded the default project Proj.LPJ is opened. It is an empty project that is taken as basis for import of user-defined production lines.







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Click on the white window in the middle of Production Supervision and import the production line Exercise_1_1.xml . To do this, first activate the setup mode by clicking on Setup in the Project menu or

clicking on the button . For Import use the command Import CIROS Project in the menu Extras -> ProjectStudio or the button . Select the appropriate XML file in the open dialog.

Ensure that the setup mode is active. The project tree in Production Supervision is still empty therefore the project must be generated.

Execute the command Generate project in the menu Extras -> ProjectStudio or use the button

to generate the project automatically.

After the project is generated you can start the production. You can find the command Production

in the Project menu or click on the button . It is recommended to deactivate the setup mode before.


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The visualization window will open and the carrier will start moving.

To manufacture a desk set click on the button Deskset in the visualization window. The button gets a blue frame which remains until the production order is completed.

You can also produce several desk sets by clicking repeatedly on Deskset, however they will be executed one by one. The other functions of the visualization windows can t be used yet since the necessary manufacturing machines are missing.

The task is now solved. You can switch to Production Simulation during the assembly of the desk set. There you can observe the process in 3D.


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3. 1. 3 Solution 1.3: Extending a production line and producing a base plate as well as a penholder

Note

Attention

Solution

If Production Supervision is in production mode deactivate it. Click on Production in the menu Project or on the button .

Close Production Supervision when the production mode is deactivated. Switch to Production Simulation and execute Reset Workcell in the menu Simulation. The production line will be reset. If Production Simulation isn t running, start it and load the production line Exercise_1_1.mod .

Save the production line with a new name by clicking on Save As

in the File menu. Choose Exercise_1_3.mod as new file name.

Change the view to Top View which you can find in the View -> Standard Views menu. You can change the view with the right mouse button as well if the edit mode is inactive. Now activate the edit mode with the command Edit Mode in the

Modeling menu or click on this button .

Open the model libraries window by clicking on the button

or the command Model Libraries

in the Modeling menu.







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Search for the entry Station Mill & Turn RV-3SB in the model libraries and select it. Add the model to the 3D editor with a double click or the Button Add.

The mill and turn station should be highlighted in green, if that isn t the case click once on it. Move, with pressed left mouse button, the coupling point of the selected model to the coupling point on the right of the transport system. When you release the mouse button the model should align. If it doesn t the two coupling points weren t exactly on top of each other. Try it again and it is important that you have selected the Top View before.

When the mill and turn station is connected, select the Station Handling& Quality in the model libraries window and add it to the work space by double clicking or using the Add button. Drag the coupling point of the model to the coupling point on the top right of the transport system. If the two coupling points are on top of each other you can release the left mouse button and the model will align.


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The modifications are done therefore deactivate the edit mode the with the command Edit Mode in

the Modeling menu or the button .

Since the production line has changed a new XML file must be created for Production Supervision. Click on Create plant

in the menu Extras or on the

button . Save the XML file as Exercise_1_3.xml .

Now start Production Supervision ProjectStudio and click on the empty window in the middle to unlock the button of the toolbar on the top left.


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Import and generate the changed production line in Production Supervision. Use the command Import CIROS Project in the menu Extras -> ProjectStudio or the

button . Then click on the button

or in the menu Extras->ProjectStudio on Generate project. Mind that for generation the edit mode must be active that means either there is a tick on Setup in the Project menu or the

button

is pressed. If you have saved the changed production line with the same name then Production Supervision indicate that a project with the same name already exists. Confirm the message box with a click on OK to overwrite the old project.

Test the modified production line by starting the production mode. Use the command Production in

the Project menu or the button .


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As soon as the visualization window is loaded you can produce a base plate as well as a penholder. Click on the buttons Baseplate and Penholder. Thereupon Production Supervision will ask you whether the raw material for the penholder should be taken from stock or the feeder on the mill and turn station (ProdPenholder or ProdPenholderMag). Choose ProdPenholder so that the stock is used. For the baseplate you will get the same question and choose ProdBaseplate to use the stock as well. If a message box appears which says that a necessary part isn t in stock confirm it so that the part will be produced.

Since the modified production line contains all necessary stations you can use the three standard strategies as you like. However the stock contents should receive attention.

The task is now solved. You can switch to Production Simulation during the production. There you can observe the process in 3D.


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3. 1. 4 Solution 1.4: Checking and editing the stock contents

Note

Attention

Solution

Start the production mode of Production Supervision. Ensure that Production Simulation is loaded with the same production line. If that isn t the case start Production Simulation and open the model Exercise_1_3.mod . Then start

Production Supervision and open the project Exercise_1_3.lpj .

Open the iCIM Production Manager. Click on Database in the displayer visualization window.







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To be able to modify the stock contents you first have to login. Click on the button Login in the top right corner of the database window. Use User as username and Festo as password.

Then click in the database window on Stock Contents.

To fill the warehouse with the default contents a click on Copy from Stock Init will do. After a short calculating time the stock contents will be changed.


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Now change to the visualization window. Click on the Penholder button to start the strategy for a penholder. If a message box appears which asks whether ProdPenholder or ProdPenholderMag should be used, choose ProdPenholder.

Switch to Production Simulation to see how the raw material for the penholder is moved to the transport system. A following switch back to the database window shows that storage bin No. 2 now contains a 0 which means it is empty.


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Select the empty storage bin by clicking on it. Type in a 0 in the input field Order No. and as Part No. type in 42000 . Click on Modify to apply the changes. The storage bin now contains the raw material again.

As soon as the penholder is manufactured in the CNC machine it will be moved on the transport system and sent back to the stock. Since the stock now has no empty storage bin the penholder can t be transfer to stock.


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Select the storage bin No. 40 with the left mouse button. Enter a 0 in the input field Part No. and click on Modify. This way the storage bin is emptied and the penholder can be transferred to stock.

Switch to Production Simulation and observe whether the produced penholder is placed into stock without errors. If you haven t emptied storage bin No. 40 in time a error dialog will appear that says the stock is full. Ignore the error message and empty storage bin No. 40 then choose Retry in the error dialog and click on OK. Production Supervision will try to place the penholder into stock again which should be error-free now.

The task is solved now. You can make any changes in the stock contents you like. Take the part list in the appendix to associate the part number with the different products.


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3. 1. 5 Solution 1.5: Creating an orders list and differing between order numbers

Note

Attention

Solution

a) Create an orders list which produces a base plate type 4 as well as a desk set which consists of a base plate type 3, a messing penholder type 3 and a pen.

Start the production mode of Production Supervision. Ensure that Production Simulation is loaded with the same production line. If that isn t the case start Production Simulation and open the model Exercise_1_3.mod . Then start Production Supervision and open the project Exercise_1_3.lpj .

Open the iCIM Production Manager. Click on Database in the displayer visualization window.







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To be able to modify an orders list you first have to login. Click on the button Login in the top right corner of the database window. Use User as username and Festo as password.

Then click on Orders listed in the database window to open the window for the orders list.

To add orders to the orders list enter the desired date in the input fields.


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The base plate 4 has the part number 42143 . Enter it in the input field for Part

No. You can either enter it directly or click on the arrow to choose from a list.

Enter 0 in Order No. and leave the 1 in the Cusomter No. input field. To produce a product with a certain order number the necessary part in stock has to have the same order number. By default all parts have the order number 0 . The customer number assigns the order to a customer which is defined under the Customers button in the database window.

The input field Resource lets you select the

station on which the part should be manufactured. In this case only MillandTurnRV3SB is available so choose it. Click on the Add button and the inputs will be recorded below Orders scheduled. Any more orders can be added but keep in mind that the orders are started simultaneously. That means if for example a station only has 4 buffers and you define 5 orders for this station the fifth order can be executed.


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The desk set which is to manufacture has the part number 52946 . Enter it in the input fields in the same way as with the base plate. That is Part No. is 52946 , Order No. is 0 and Customer No. stays 1 . For Resource select the AssemblyRV3SB station. A click on the Add button adds the order to Orders scheduled.

It is wise to always check the stock contents or loading the default contents before starting an orders list. Else it might happen that necessary parts aren t available in stock. Open the stock contents by clicking on Stock Contents in the right navigation bar of the database window. Then click on Copy from Stock Init to load the default contents.


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Switch to the visualization window and click on Orders listed to start the production orders. You can observe the state of the orders list in the database window. After execution the production orders are moved to Orders running and as soon as an order is complete it is moved to Orders finished. There you can see if an order was processed successful or if an error occurred.

After the production orders are finished click on Clean up to remove them from the Orders finished list.


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b) Produce the aluminium penholder type 1 with order number 0 and 1 . Edit the stock contents if necessary.

The penholder type 1 has the part number 42100 . Open the orders list window by

clicking on Orders listed in the database window.

Enter 42100 as Part No. As Order No. Enter a 0 und choose MillandTurnRV3SB as Resource. Add the order to the orders list with the Add button.

Click on the order below Orders scheduled. The input fields are filled with the contents of that order. Change Order No. to 1 and add the modified order with the Add button to Orders scheduled.


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Check the stock contents before executing the orders list. It is important that the raw material for both orders is available. The raw material has the part number 42000 .

Open the stock contents by clicking on Stock Contents in the right navigation bar of the database window. Then click on Copy from Stock Init to load the default contents. There should be some storage bins with the raw material 42000 now but they all have the order number 0 . Therefore the first production order will run without errors while the second order with Order No. 1 will error since the necessary raw material isn t available. For this reason it is important to check the order numbers in stock as well when using an orders list. The order number reserves the particular part for an order with the same order number.

Select any storage bin with the part number 42000 and enter a 1 in the input field for Order No. and apply the change with a click on Modify.


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Switch to the visualization window of Production Supervision and start the orders list with the Orders Listed button. This button gets a blue frame until the processing of the orders list is completed.

You can observe the state of a production order and see when it is completed in the database window.

The task is solved. Now you can manufacture any part with an orders list. But keep in mind that all orders are started simultaneously and there have to be enough buffers. Also ensure that the necessary parts are available in stock.


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3. 1. 6 Solution 2.1: Creating a new deskset and manufacturing it

Note

Attention

Solution

Start Production Simulation and load the production line Exercise1-3.mod. Then start Production Supervision and load the project Exercise1-3.LPJ.

Start production mode by clicking on the command Production in the menu Project or by clicking on the button .

The visualization window for process operating and display opens automatically after initialization of production mode.

Click on the button Database to see the tables of production database and to edit them.

The opening screen iCIM Production Manager of the database opens.

You can not modify the database unless you are logged in. So click on Login and use Instructor//didactic as account data. The user Instructor has full write access to the database.







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Click on the button Products to open the parts list.

Since the deskset 100000 is based upon the deskset 50000 it is wise to use it as template. Select the part number 50000 in the checkbox next to Part No.

Click on the button Create New. A dialog window will open to ask you for a new part number. Enter 100000 as part number and confirm it with a click on OK.

The next dialog asks you whether the current selected data set should be used as template. Answer the question with the button Yes.


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Another option dialog shows up which asks about construction data of the new part. There are 3 options. You can decide if an empty entry, an entry with the construction data of the template or no entry should be created. Since the new deskset differs hardly from the template you can take over the existing construction data and change them. Therefore select the middle option and click on OK.

Now the entries of the part 50000 are automatically applied to the part 100000 .

Since the deskset 100000 is a new part it is reasonable to change the name and description. Therefore enter the Name Deskset 100000 Tested and change in the Description the word penholder alu type 1 to penholder brass type 1. The description is to describe the assembly of the desket.

Click on Save to save the changes in the new data set. The data set with the attributes of the new part is now element of the production database. Next step is to adapt construction data.


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Click on the button CIROS Construction in the top window area to see the window for construction data. There select the part number 100000 .

Search for the expression GP_PenholderAluType1 which paints a aluminium penholder. However the deskset 100000 has a brass penholder so change that entry to GP_PenholderBrassType1.

Click on Save to save the modified construction data. Before the new part can be produced appropriate data for the production process has to be entered in the database.

Click in the database window on the button Production Data to see a list of production process of the parts.

Select 100000 below Part No.. You will get a hint that for that part number no production processes are defined. Confirm the message box.

In the group Resource Properties select under Resource Class the option Station FESTO Assembly since the deskset is manufactured on an assembly station. You can leave the input field Resource Name empty. With Resource Type you can choose between resource class and resource name. Always select Resource Class here, this way the part it is defined that the part can be produced on all assembly stations in general so it can be used in other projects as well. With Use Macro the macro process for the deskset can be selected. For the assembly station only AsmDeskset is available.


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In the input field Strategy under Transport Properties select ParallelTwo. Here the transport strategy is defined. For manufacturing of the deskset the two parts baseplate and penholder are needed therefore 2 carriers have to be transported to the assembly station.

In the group Subparts (supplied) parts are defined which have to be supplied by stock since they are necessary for assembly. Select in the first input field the part number 42140 for the baseplate and 42120 for the penholder in the second input field.

Click on the button Add to add the data set for the production process to the database.

The new deskset 100000 is now in the database and can be produced. Open the orders list by clicking on the button Orders listed in the database window.


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Then select below Part No. the part number 63061 for the deskset. Leave Order No. at 0 and Customer No. at 1 . For Resource select an assembly station of your production line.

Add the order to the orders list with a click on the button Add.

Switch to the visualization window of Production Supervision and start the orders list with a click on Orders Listed.

The button will get a blue frame and production of the newly added parts starts.


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3. 1. 7 Solution 2.3: Producing a baseplate with macro process tasks

Note

Attention

Solution

Ensure that Production Supervision ProjectStudio and Production Simulation have been started.

Open in both programs the same production line and ensure that the project contains a CNC mill or turn machine. A transport system and a stock station are also necessary.

Click on the window ProjectStudio in Production Supervision on the tab Process plan to see the columns of the process plan.

To produce the penholder raw material has to be transported to the CNC machine. However a carrier is needed for the transport which has to be called by the stock station. Therefore click with the right mouse button on the stock station and select the command REQUIRE in Process Task.

Enter 1 as parameter for the CarrierID in the opened dialog window.







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Afterwards put the baseplate s raw material on the stopped carrier by clicking on Process Task -> MovToTrans in the context menu of the stock. In the dialog window enter 42010 for PartNumber and leave OrderNumber at the default of 0 .

Now the raw material has to be transported to the CNC station therefore use the command to_MillAndTurn in the context menu of the CNC station under Process Task. The dialog window then asks for a CarrierID enter the 1 since you reserved this ID before.

Click with the right mouse button on the CNC machine and select Process Task -> MovFromTrans and enter the part number 42010 . With the macro process task the raw material is moved

from the transport on a buffer position of the CNC station.

Before continuing the stopper at the CNC machine should be released to guarantee a continuous material flow. Use the command RELEASE in the context menu of the CNC machine.

Now the raw material can be manufactured in the CNC machine. Click with the right mouse button on the CNC machine and select Process Task -> ProdBaseplate. The function needs the parameter TargetPartNumber so enter 42143 since that baseplate is to be produced.

After the baseplate is produced it is taken back to stock but for this a carrier is necessary. With Process Task -> REQUIRE in the context menu of the CNC machine a carrier is reserved. Since the previously reserved carrier is freed again you can use 1 as ID again.

To place the penholder on the carrier use the macro process task MovToTrans in the context menu of the CNC machine. For part number use 42143 because the produced baseplate is to be moved.

Click with the right mouse button on the stock station and select Process Task -> to_StockSingle. The carrier will then be moved to stock and stops there.

Another right click on stock and the command MovFromTrans stores the penholder in the stock. Enter 42143 as part number.

At last the stopped carrier at the stock station has to be released again. Else the material flow stops and other production processes can not be executed. Therefore click on RELEASE which you find in the context menu of the stock station and enter the ID 1 .

The process plan in the ProjectStudio window is finished and can be tested. But first it has to be generated. Activate setup mode in Production Supervision by clicking on Setup in the menu Project or

on the button .


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Click on Generate process plan in the menu Extras -> ProjectStudio to generate the process plan. As name use either Prod_User1, Prod_User2 or Prod_User3 to be able to start the process plan in the visualization window directly. Enter Prod_User1 and confirm that an existing process plan should be replaced.

Start production mode of Production Supervision with the command Production in the menu Project or

use the button .

You can start the created process plan in the visualization window by clicking on the button User 1. If you used Prod_User2 or Prod_User3 as name then click on the appropriate button.


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3. 1. 8 Solution 2.4: Replacing the macro ProdBaseplate with ExecProg tasks

Note

Attention

Solution

Ensure that Production Supervision ProjectStudio and Production Simulation have been started.

Open in both programs the same production line and ensure that it contains a milling CNC machine, a Station Mill is recommended. Also a transport system and a stock station are required.

Open in the Project window the user-defined process plan for producing a baseplate which was created with macro process tasks. If there is no such process plan create a new one. See the appropriate chapter for that.







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Scroll down in the process plan until you find the line in which the process task ProdBaseplate is used.

Highlight that line by clicking on the grey column on the left. Delete the highlighted line with the Del key or right click on the line and use the command Delete.

Then insert an empty line with the key combination Ctrl + Return or right click on the line and select Insert empty line.

Open the tasktool with the F3 key or use the command Tasktool in the menu View.

Now select the component Mill55Robot, if there is a Mill55 station in the production line. Is a different mill station connected so select its appropriate robot station.

Select ExecProg in the list box which is move to the input field. Delete the contents inside the brackets.

Inside the brackets ExecProg awaits 4 parameters. First parameter is the robot program which should be executed. The following 3 parameters are then transmitted to the robot program.

For loading the CNC machine with raw material, the robot program LMILL exists which needs 2 parameters. First parameter is the source position of the raw material and second parameters tells what kind of part it is. Enter the following in the input field of the tasktool:

ExecProg( LMILL ,1,1)

The command calls the program LMILL and indicates that raw material is on buffer position 1 . The second parameter indicates that a baseplate is loaded.


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Click left on the column Line in the empty line of the process plan. Enter a line number which is higher by 1 than the previous line. Then click on Insert to insert the process task in the empty line. The columns Device and Process Task are filled with information from the tastool.

Click in the next line and add a new line again. Enter a line number higher by 1 as well.

Since the raw material is now in the CNC machine the appropriate CNC program has to be started. Select the component Mill55CNC if there is a different mill station in the production line then select its appropriate CNC component.

Choose ExecProg in the list box and enter the following in the input field of the task tool:

ExecProg(143)

The CNC machine only needs one parameter and that is what CNC program should be started. More is not necessary. The CNC program is determined by the last 3 digits of the part number. However it is important that the target part number is used since the appropriate part is to be produced.

One click on Insert takes over the process task from tasktool to the process plan


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The baseplate is now manufactured. The next step is to move it back on the pallet. For this the robot program ULMILL is used. It needs 2 parameters like LMILL and the first one indicates the target buffer position while the second one tells if a penholder or baseplate is used. Therefore click in the next line and add a new line again. Enter a line number higher by 1 as well.

Select component Mill55Robot in the tasktool again and choose ExecProg in the list box. Enter then in the input field the following process task:

ExecProg( ULMILL ,1,1)

The command calls the program ULMILL and indicates that the produced baseplate is to be put on buffer position 1 . The second parameter indicates that a baseplate is used.

Add the process task in the empty line by clicking on Insert.

The modification in the process plan is now finished. The three inserted process tasks replace the macro process task ProdBaseplate. Save the process plan with the command Save all in the menu File

or use the button .

Close the process plan. To see if the user-defined process plan has no syntax errors right click on it in the project window and select the option Check. The message window shows occurred errors or warnings. A double click on an error or warning opens the process plan automatically and focuses the problematic line.


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Before the process plan can be executed Production Supervision has to be in production mode. Click therefore on Production in the

menu Project or use the button .

As soon as the window for starting production is closed automatically switch to Production Supervision. Right click on the process plan and the command Start executes it. If the process plan is saved as a user-defined process plan you can also use the User buttons in the visualization window.

Observe the process in Production Simulation and in the visualization window.


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3. 2 Parts list

PartNo

ProdName Description 0

Shelf Empty Shelf (empty) in stock 30000

Instrument Thermometer Thermometer in feeder 30001

Instrument Hygrometer Hygrometer in feeder 30002

Instrument Magnet Magnet in feeder 30100

Instrument Pen Pen in feeder 32000

Raw Part Penholder Alu Penholder alu raw material in feeder 32001

Raw Part Penholder Brass Penholder brass raw material in feeder 32010

Raw Part Baseplate Alu Baseplate alu raw material in feeder 42000

Penholder Alu Raw Penholder alu raw material on penholder pallet 42001

Penholder Brass Raw Penholder brass raw material on penholder pallet 42010

Baseplate Alu Raw Baseplate alu raw material on baseplate pallet 42100

Penholder Alu Type1 Penholder alu type 1 (empty) on penholder pallet 42101





Penholder Brass Type1 Penholder brass type 1 (empty) on penholder pallet 42121




Penholder Brass Type5 Penholder brass type 5 (empty) on penholder pallet

42140

Baseplate Alu Type1 Baseplate alu type 1 (empty, empty, empty) on baseplate pallet

42141


42142


42143


42144


46140

Baseplate Alu Type1 Tested Tested baseplate alu type 1 (empty, empty, empty) on baseplate pallet

46141


46142


46143


46144


50000

Deskset 50000 Deskset (baseplate alu type 1 (empty, empty, penholder alu type 1 (empty))) on baseplate pallet


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50155

Deskset 50155 Deskset (baseplate alu type 4 (hygrometer, empty, penholder alu type 2 (empty))) on baseplate pallet

50257

Deskset 50257 Deskset (baseplate alu type 2 (empty, empty, penholder alu type 3 (empty))) on baseplate pallet

50755

Deskset 50755

Deskset (baseplate alu type 4 (thermometer, hygrometer, penholder brass type 1 (pen))) on baseplate pallet

50924

Deskset 50924

Deskset (baseplate alu type 5 (hygrometer, empty, penholder brass type 3 (empty))) on baseplate pallet

51018

Deskset 51018

Deskset (baseplate alu type 3 (hygrometer, hygrometer, penholder brass type 3 (empty))) on baseplate pallet

51137

Deskset 51137

Deskset (baseplate alu type 2 (thermometer, hygrometer, penholder brass type 4 (empty))) on baseplate pallet

52368

Deskset 52368 Deskset (baseplate alu type 1 (empty, thermometer, penholder alu type 3 (pen))) on baseplate pallet

52648

Deskset 52648

Deskset (baseplate alu type 1 (hygrometer, thermometer, penholder alu type 5 (pen))) on baseplate pallet

52675

Deskset 52675

Deskset (baseplate alu type 4 (thermometer, hygrometer, penholder alu Type 5 (pen))) on baseplate pallet

52834

Deskset 52834 Deskset (baseplate alu type 3 (thermometer, empty, penholder brass type 2 (pen))) on baseplate pallet

52946

Deskset 52946 Deskset (baseplate alu type 3 (empty, empty, penholder brass type 3 (pen))) on baseplate pallet

53060

Deskset 53060

Deskset (baseplate alu type 5 (thermometer, hygrometer, penholder brass type 3 (pen))) on baseplate pallet

60000

Deskset 60000 Tested Deskset (tested baseplate alu type 1 (empty, empty, penholder alu type 1 (empty))) on baseplate pallet

60155

Deskset 60155 Tested

Deskset (tested baseplate alu type 4 (hygrometer, empty, penholder alu type 2 (empty))) on baseplate pallet

60257

Deskset 60257 Tested Deskset (tested baseplate alu type 2 (empty, empty, penholder alu type 3 (empty))) on baseplate pallet

60755


Deskset (tested baseplate alu type 4 (thermometer, hygrometer, penholder brass type 1 (pen))) on baseplate pallet

60924


Deskset (tested baseplate alu type 5 (hygrometer, empty, penholder brass type 3 (empty))) on baseplate pallet

61018


Deskset (tested baseplate alu type 3 (hygrometer, hygrometer, penholder brass type 3 (empty))) on baseplate pallet


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61137


Deskset (tested baseplate alu type 2 (thermometer, hygrometer, penholder brass type 4 (empty))) on baseplate pallet

62368


Deskset (tested baseplate alu type 1 (empty, thermometer, penholder alu type 3 (pen))) on baseplate pallet

62648


Deskset (tested baseplate alu type 1 (hygrometer, thermometer, penholder alu type 5 (pen))) on baseplate pallet

62675


Deskset (tested baseplate alu type 4 (thermometer, hygrometer, penholder alu Type 5 (pen))) on baseplate pallet

62834


Deskset (tested baseplate alu type 3 (thermometer, empty, penholder brass type 2 (pen))) on baseplate pallet

62946

Deskset 62946 Tested Deskset (tested baseplate alu type 3 (empty, empty, penholder brass type 3 (pen))) on baseplate pallet

63060


Deskset (tested baseplate alu type 5 (thermometer, hygrometer, penholder brass type 3 (pen))) on baseplate pallet

82200

Pallet Penholder Penholder pallet (empty) 82201

Pallet Baseplate Baseplate pallet (empty)

92140

Baseplate Alu Type1 Defective

Defective baseplate alu type 1 (empty, empty, empty) on baseplate pallet

92141



92142



92143



92144



CIROS Production Advance

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