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MODEL HIGH LEVEL STORAGE WAREHOUSE

WITH CONNECTION STS

Contents

1.- Introduction 2.- Model description

2.1 High level storage warehouse 2.2 Rail guided vehicle STS

3.- Actuators and sensors connections 4.- Electrical wiring diagrams

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1. Introduction. Currently, the ITESM System is implementing a Remote Laboratories Network in different Campus in México. Each Campus has the compromise to install and operate a different model, and then, the models could be used by the students of the Campus. The complete system consists in the following components:

PC station

PLC- S7 300

Scale model

Two video cameras

Power supply

LabView software

Simatic Step 7

The model in Campus Laguna consists of the following main parts:

High level storage warehouse

Rail guide vehicle STS

2. Model description.

2.1 High level storage warehouse

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The High Level Storage Warehouse simulates an automatically working high-level-storage system as used for example in many industries branches. The model consists of a rack, being divided up in 5 x 10 storage places, a warehouse operating device, being portable in X-direction, and two charge / discharge stations. A cage being portable in Z-direction and including a telescopic carrier, that is portable in Y-direction, is attached to the warehouse operating device. The simulated process shows palettes being stored and withdrawn from the high-level storage: In case of one charge station being occupied by a palette, the telescopic palette carrier moves to the station and takes over the palette. This is recognized by a reflection light switch. Following this, the warehouse operating device brings the palette to the intended storage place in an optimized manner by moving in X- and Z- direction at the same time. Occupying a storage place is recognized by software. In order to enable a quick movement to the storage place on the one hand and a safe lay-in-movement on the other hand, the horizontal rack positions are equipped with advanced mechanical switches that allow retarding the warehouse operating device before reaching the intended position. Withdrawing palettes occurs in the same manner, done in inverse chronological order. In cause of bolting the Y-axes against the two others moving the palette carrier in X- and Z-direction is only possible, if the palette carrier is in its middle position. Moreover, the X-axis is equipped with a hardware end position switch to prevent the whole warehouse system from fatal mistakes in using the conveyor or programming the control unit. The High-level-Storage warehouse is fit to be combined with further modules and standard models in order to automate the peripheral of the warehouse.

Technical Data Power supply of sensors and actuators: 24 VDC

Sensors:

Control system requirements:

Reflection light switches : 2 One way light barrier : 1 Magnetic Sensor (readers) : 4 Mechanical switches : 25

Digital inputs : 26 Digital output : 11

Actuators: Motors with two directions : 5

Dimension (W x D x H) 1000 x 140 x 100 mm

Technical data of sensors and actuators can be borrowed from the corresponding data sheets.

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2.3 Rail guided vehicle STS

The Rail guided vehicle STS is an element of a flexibly configurable transport system. Compared to conveyor belts it allows a more flexible transport of work pieces over big distances. The Rail guided vehicle consists of the shuttle, which is fitted with an inductive proximity switch to recognize parts on it and two tracks with a length up to 1 m and 2 stop positions. Several modules with feeding functions can be used to hand over parts to the STS. Reaching the exact stop positions for taking over a part is ensured by mechanical switches.

Technical Data

Sensors:

Control system requirements:

Inductive proximity switches : 1 Mechanical switches : 2

Digital inputs : 4 Digital output : 4

Actuators: Motors with two directions : 2

Dimension (W x D x H) 1000 x 140 x 100 mm

Technical data of sensors and actuators can be borrowed from the corresponding data sheets.

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3. Actuators and sensors connections The pin-outs configuration is shown in Tables 1, 2, 3 and 4.

Table 1. Digital input variables

X1

PLC Electrical wiring diagram PLC Input address

Module

Module Connector

Connector DB37-X1

Cable Color

Description/function

Symbol

I0.0 1 2 1 OR-YE █ █ X-axis at position 1 3S1 Pos_X_01

I0.1 1 3 2 YE-OR █ █ X-axis at position 2 3S2 Pos_X_02

I0.2 1 4 3 RD-GY █ █ X-axis at position 3 3S3 Pos_X_03

I0.3 1 5 4 GY-RD █ █ X-axis at position 4 3S4 Pos_X_04

I0.4 1 6 5 GY-BK █ █ X-axis at position 5 3S5 Pos_X_05

I0.5 1 7 6 BK-GY █ █ X-axis at position 6 3S6 Pos_X_06

I0.6 1 8 7 OR-BK █ █ X-axis at position 7 3S7 Pos_X_07

I0.7 1 9 8 BU-OR █ █ X-axis at position 8 3S8 Pos_X_08

I1.0 1 12 9 BN-WH █ █ X-axis at position 9 3S9 Pos_X_09

I1.1 1 13 10 WH-BN █ █ X-axis at position 10 3S10 Pos_X_10

I1.2 1 14 11 GY-YE █ █ Y-axis at position Y- 4S3 Pos_Y_01

I1.3 1 15 12 YE-GY █ █ Y-axis in the middle 4S4 Pos_Y_02

I1.4 1 16 13 GN-WH █ █ Y-axis at position Y- 4S5 Pos_Y_03

I1.5 1 17 14 WH-GN █ █ Z-axis above position 1 (Z+) 4S6 Pos_Z_01

I1.6 1 18 15 VT-OR █ █ Z-axis below position 1 4S7 Pos_Z_11

I1.7 1 19 16 OR-VT █ █ Z-axis above position 2 4S8 Pos_Z_02

- - 17 RD-GN █ █ Spare -

1 20 18 GN-RD █ █ Power Supply 0V. -

1 20 19 YE-GN █ █ Power Supply 0V. -

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Table 2. Digital input variables

X1

PLC Electrical wiring diagram PLC Input address

Module

Module Connector

Connector DB37-X1

Cable Color

Description/function

Symbol

I4.0 2 2 20 GN-YE █ █ Z-axis below position 2 5S1 Pos_Z_12

I4.1 2 3 21 BU-RD █ █ Z-axis above position 3 5S2 Pos_Z_03

I4.2 2 4 22 RD-BU █ █ Z-axis below position 3 5S3 Pos_Z_13

I4.3 2 5 23 YE-BU █ █ Z-axis above position 4 5S4 Pos_Z_04

I4.4 2 6 24 BU-YE █ █ Z-axis below position 4 5S5 Pos_Z_14

I4.5 2 7 25 BN-RD █ █ Z-axis above position 5 5S6 Pos_Z_05

I4.6 2 8 26 RD-BN █ █ Z-axis below position 5 (Z-) 5S7 Pos_Z_15

I4.7 2 9 27 YE-BN █ █ Rack Feeder Engaged 5S8 Press_Feeder

I5.0 2 12 28 BN-YE █ █ I/O Station 1 6S1 Press_STA1

I5.1 2 13 29 WH-OR █ █ I/O Station 2 6S2 Press_STA2

I5.2 2 14 30 OR-WH █ █ STS workpiece Present 6S3 Press_STS

I5.3 2 15 31 BU-WH █ █ STS pos. X- 6S4 STSPosX_01

- - 32 WH-BU █ █ STS in the middle 6S5 NO EN PLC

I5.4 2 16 33 GY-WH █ █ STS pos. X+ 6S6 STSPosX_03

- - 34 WH-GY █ █ Spare -

- - 35 VT-GN █ █ Spare -

2 1 36 GN-VT █ █ Power Supply Motors -

2 1 37 GY-VT █ █ Power Supply Sensors -

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Table 3. Digital output variables

X2

PLC Electrical wiring diagram PLC Output address

Module

Module Connector

Connector DB37-X2

Cable Color

Description/function

Symbol

Q0.0 1 22 1 OR-YE █ █ X-axis to X+ 7S1 11M1_XPOS

Q0.1 1 23 2 YE-OR █ █ X-axis to X- 7S2 11M1_XNEG

Q0.2 1 24 3 RD-GY █ █ a-axis slow 11K2 11M1_SLOW

Q0.3 1 25 4 GY-RD █ █ Y-axis to Y- 12A1 11M2_YNEG

Q0.4 1 26 5 GY-BK █ █ Y-axis to Y+ 12A1 11M2_YPOS

Q0.5 1 27 6 BK-GY █ █ EZ-axis to Z+ 12A1 11M3_ZPOS

Q0.6 1 28 7 OR-BK █ █ Z-axis to Z- 12A1 11M3_ZNEG

Q0.7 1 29 8 BK-OR █ █ I/O Station 1 release from stock 12A2 12M4_YNEG

Q1.0 1 32 9 BN-WH █ █ I/O Station 1 Place into stock 12A2 12M4_YPOS

Q1.1 1 33 10 WH-BN █ █ I/O Station 2 release from stock 12A2 12M5_YNEG

Q1.2 1 34 11 GY-YE █ █ I/O Station 2 Place into stock 12A2 12M5_YPOS

Q1.3 1 35 12 YE-GY █ █ STS conveyor belt to Y+ 13A1 13M1_YPOS

Q1.4 1 36 13 GN-WH █ █ STS conveyor belt to Y- 13A1 13M1_YNEG

Q1.5 1 37 14 WH-GN █ █ STS drive to X+ 13A1 13M2_XPOS

Q1.6 1 38 15 VT-OR █ █ STS drive to X- 13A1 13M2_XNEG

- - 16 OR-VT █ █ Spare -

- - 17 RD-GN █ █ Spare -

1 40 18 GN-RD █ █ Power Supply 0V. -

1 40 19 YE-GN █ █ Power Supply 0V. -

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Table 4. Digital input variables

X2

PLC Electrical wiring diagram PLC Input address

Module

Module Connector

Connector DB37-X2

Cable Color

Description/function

Symbol

- - 20 GN-YE █ █ Spare -

- - 21 BU-RD █ █ Spare -

- - 22 RD-BU █ █ Spare -

- - 23 YE-BU █ █ Spare -

- - 24 BU-YE █ █ Spare -

- - 25 BN-RD █ █ Spare -

- - 26 RD-BN █ █ Spare -

- - 27 YE-BN █ █ Spare -

I5.5 2 17 28 BN-YE █ █ Reading Station 1 Sensor 1 10S1 ReadS11

I5.6 2 18 29 WH-OR █ █ Reading Station 1 Sensor 2 10S2 ReadS12

- - 30 OR-WH █ █ Reading Station 2 Sensor 1 10S3 ReadS21

- - 31 BU-WH █ █ Reading Station 2 Sensor 2 10S4 ReadS22

- - 32 WH-BU █ █ Spare -

- - 33 GY-WH █ █ Spare -

- - 34 WH-GY █ █ Spare -

- - 35 VT-GN █ █ Spare -

2 21 36 GN-VT █ █ Power Supply Motors -

2 21 37 GY-VT █ █ Power Supply Motors -

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6S4 6S6 6S5

6S11 6S12

6S1

12M4

6S21 6S22

6S2

12M5

4S5 4S3 4S4

4S7

4S6

5S1

5S8

5S3 5S2

5S5 5S4

5S7 5S6

5S8

11M3

11M2

6S3 13M1

13M2

12M4

11M1

12M5

13M1

11M2

11M3

13M2

3S1 3S2 3S3 3S4 3S5 3S6 3S7 3S8 3S9 3S10

HIGH LEVEL STORAGE WAREHOUSE

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4.- Diagramas eléctricos Electrical wiring diagrams for digital inputs and outputs

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- Layout system