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“Besides black art, there is only automation and mechanization.” Federico Garcia Lorca
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“Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

Jan 01, 2016

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Page 1: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

“Besides black art, there is only automation and mechanization.”

Federico Garcia Lorca

Page 2: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

The Gantry Automation Project Overview

The Objective

s

Our Approach

How it was

programed

The Logic Codes

The Final Result

Rhys Porter , Joseph Eric Roy, Anthony Moody

Page 3: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

The Objectives

To Solve a Puzzle Using Automation

H0 H1 H2 H3 H4

V0

V1

V4

V2

V3

Green

Amber

Red

Page 4: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

The Objectives

To Solve a Puzzle Using Automation

H0 H1 H2 H3 H4

V0

V1

V4

V2

V3

Green

Amber

Red

Page 5: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

The Objectives

To Solve a Puzzle Using Automation

H0 H1 H2 H3 H4

V0

V1

V4

V2

V3

Green

Amber

Red

Page 6: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

The Objectives

The Puzzle Solved State

H0 H1 H2 H3 H4

V0

V1

V4

V2

V3

Green

Amber

Red

Page 7: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

Our Approach

Understand the task, then

Define the sequences

Page 8: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

How it’s going to be done

H0 H1 H2 H3 H4

V0

V1

V4

V2

V3

Green

Amber

Red

Page 9: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

Stack all the disks together

H0 H1 H2 H3 H4

V0

V1

V4

V2

V3

Green

Amber

Red

Page 10: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

H0 H1 H2 H3 H4

V0

V1

V4

V2

V3

Green

Amber

Red

Measure the disks

Page 11: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

Till the puzzle is solved

H0 H1 H2 H3 H4

V0

V1

V4

V2

V3

Green

Amber

Red

Page 12: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

“Controlling complexity is the essence of computer programming”

(Brian Kernigham)

Page 13: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

S1 : Dormant

LightsS100-199

S2 : Starting

LightsS200-299

S3 : Recover

ActionsS300-349

LightsS350-399

S4 : E-

Stopped

LightsS400-499

S5 : Running

StackingS1000-1499

SortingS1500-1999

LightsS350-399

Hierarchical State Machine Design

Page 14: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

Resource AllocationName Main State Sub-States State Memory Other Memory Timers

Primary – S0-9 M0.0-3.7 M4.0-9.7 T0-9

Powerup S0 – – – –

Dormant S1 S100-199 M10.0-13.7 M14.0-19.7 T10-19

Starting S2 S200-299 M20.0-23.7 M24.0-29.7 T20-29

Recover S3 S300-349 M30.0-33.7 M34.0-34.7 T30-34

Recover+Run Lights S3 S350-399 M35.0-38.7 M39.0-39.7 T35-39

E-Stop S4 S400-499 M40.0-43.7 M44.0-49.7 T40-49

Running: Stacking S5 S1000-1499 M100.0-103.7 M104.0-149.7 T100-149

Running: Sorting S5 S1500-S1999 M150.0-M153.7 M140.0-199.7 T150-199

Recover+Run Lights S5 S350-399 M35.0-38.7 M39.0-39.7 T35-39

Page 15: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

Interaction of Main States

Page 16: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

Interaction of Main States (Simplified)

Page 17: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

Benefits of a Hierarchical State Machine• Minimises code duplication

• Eg “Go Home” memory bit to return to HO,VO

• Easy to follow debugging• Ability to see states the PLC is in at any point

• Any sub-state bugs are contained• Use of function calls and sub-state re-initialisation and clean up

• Mutated sub-state behaviour based on “Flag” memory bits set• Eg Different Lighting behaviours or stacking columns

Page 18: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

“If you don’t trust them, then program them”

Machines

(Joseph Eric Roy)

Page 19: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

Gantry Simulation

Page 20: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.
Page 21: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.
Page 22: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.
Page 23: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

Physical Constraints • Speed• Simulation• Suction

• Time• Over extension

• Switch location• S7-300 PLC• TIA portal software

Page 24: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

Stacking State

Page 25: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.

Recovery State

Page 26: “Besides black art, there is only automation and mechanization.” Federico Garcia Lorca.