Factory IO Siemens PLC Simulator Tutorial
This video supports the free online Open Production Line Factory IO project and lesson at Open Production Line Factoryio
(Download the lesson's free Factory IO project files at the link above.)
Jump to:
1:03 Closed Production Line
1:52 Open Production Line
3:58 Siemens S7 300 Programming Tutorial
4:51 PLC Programming Best Practices
5:29 Adding Remote Operator Control Panels
6:31 PLC Programming Naming Conventions
6:44 Download Instructions for Factory IO projects
NOTE: This lesson requires students to download and install the Factory IO and Siemens simulation software. The lesson page above has a purchase option if needed. Project file downloads and lessons are free.
Video Transcript:
Welcome to BIN95's Siemens/Factory IO Open Production Line example and exercise.
Factory IO simulation software allows users to build and test open production lines. The factory simulation software uses modular machines and equipment. It allows for different parts, colors, etc. Users can switch between products or production types.
This lesson will use the WinSPS S7 Siemens PLC simulation software for automation control. We will take a look under the hood later in this video. Like in PLC programming and troubleshooting, we will first get familiar with the Open Production Line example's system and operation.
This production line makes bases and lids using two machining centers. The automation control comprises a Siemens S7-300, a mainline control panel, and two machining center control panels.
[Closed Production Line Operation]
The operator presses the run button, the line switches to auto mode, and Cell 1 starts producing bases and Cell 2 lids. There are counters for each. The stop button removes the line from auto mode; no new raw material enters the cells. The cells finish their work in progress and then stop.
Before we added automation to make this line an open production line, running a batch in one cell required the whole line to be shut down. Closed production lines are inflexible.
[Open Production Line Operation]
In this new version you will download, operators can place any cell in "Batch Mode" or stop if there is an issue while the rest of the cells in the production line continue to run. Also, while updating the PLC logic, we found there needed to be an indicator on the remote system control panel to let operators know one of the cells has an issue or that a cell is offline while running a special batch of products.
On the main system control panel, the yellow light for each cell will blink if the cell cycle time is longer than expected. It will be solid yellow if the operator places the cell in "Batch mode". Also, the reset button resets the counters on the main control panel.
The "Stop" button on individual cell control panels stops the robot. The "Start" button will allow the robot and machining center to continue where it left off. The cell "Reset" button will eject the part regardless of whether it is finished or not, making the cell ready to produce new parts.
The green "Auto" lamp on cell control panels lets the operator know the entire line is currently in auto mode. All control panels have indicators from other panels. Open production lines may be reconfigured so that each cell or control panel is no longer visible at all locations. Thus, there is a need for status indicators on remote control panels.
[Programming Siemens S7 300 Simulator]
Let's explore the programming behind the open production line automation control. For this exercise, we use Siemens Simatic S7 300 PLC programming language. The PLC simulator used is WinSPS-S7. Also referred to as WinPLC7.
While this is an old Siemens PLC simulator and processor, it gets the job done. Not every machine you run into in manufacturing has the newest PLCs and software. Many will be older versions that are still doing the job.
Let's take a tour of the ladder logic controlling this. We will skip over the rungs covered previously in the beginner lesson. We must focus on our changes to convert to an open line with educational tidbits added. After watching this video, the best approach is to download the project from the lesson page and study the code.
The best practice is to use standard industry naming conventions and tags instead of addresses as much as possible. So, we changed the "Run" tag to "Auto" and replaced addresses with tags. [picture not-best-practice.jpg] Also, each rung with a descriptive rung comment is best practice. As this PLC simulator software does not support that feature, we at least add network comments to help others read through the program.
The first two rungs of Network 7 are an example of creating a one-second pulse if your PLC brand does not already have a more efficient one-second pulse bit like the one the Allen-Bradley PLC brand has...
(Download the lesson's free Factory IO project files at the link above.)
Jump to:
1:03 Closed Production Line
1:52 Open Production Line
3:58 Siemens S7 300 Programming Tutorial
4:51 PLC Programming Best Practices
5:29 Adding Remote Operator Control Panels
6:31 PLC Programming Naming Conventions
6:44 Download Instructions for Factory IO projects
NOTE: This lesson requires students to download and install the Factory IO and Siemens simulation software. The lesson page above has a purchase option if needed. Project file downloads and lessons are free.
Video Transcript:
Welcome to BIN95's Siemens/Factory IO Open Production Line example and exercise.
Factory IO simulation software allows users to build and test open production lines. The factory simulation software uses modular machines and equipment. It allows for different parts, colors, etc. Users can switch between products or production types.
This lesson will use the WinSPS S7 Siemens PLC simulation software for automation control. We will take a look under the hood later in this video. Like in PLC programming and troubleshooting, we will first get familiar with the Open Production Line example's system and operation.
This production line makes bases and lids using two machining centers. The automation control comprises a Siemens S7-300, a mainline control panel, and two machining center control panels.
[Closed Production Line Operation]
The operator presses the run button, the line switches to auto mode, and Cell 1 starts producing bases and Cell 2 lids. There are counters for each. The stop button removes the line from auto mode; no new raw material enters the cells. The cells finish their work in progress and then stop.
Before we added automation to make this line an open production line, running a batch in one cell required the whole line to be shut down. Closed production lines are inflexible.
[Open Production Line Operation]
In this new version you will download, operators can place any cell in "Batch Mode" or stop if there is an issue while the rest of the cells in the production line continue to run. Also, while updating the PLC logic, we found there needed to be an indicator on the remote system control panel to let operators know one of the cells has an issue or that a cell is offline while running a special batch of products.
On the main system control panel, the yellow light for each cell will blink if the cell cycle time is longer than expected. It will be solid yellow if the operator places the cell in "Batch mode". Also, the reset button resets the counters on the main control panel.
The "Stop" button on individual cell control panels stops the robot. The "Start" button will allow the robot and machining center to continue where it left off. The cell "Reset" button will eject the part regardless of whether it is finished or not, making the cell ready to produce new parts.
The green "Auto" lamp on cell control panels lets the operator know the entire line is currently in auto mode. All control panels have indicators from other panels. Open production lines may be reconfigured so that each cell or control panel is no longer visible at all locations. Thus, there is a need for status indicators on remote control panels.
[Programming Siemens S7 300 Simulator]
Let's explore the programming behind the open production line automation control. For this exercise, we use Siemens Simatic S7 300 PLC programming language. The PLC simulator used is WinSPS-S7. Also referred to as WinPLC7.
While this is an old Siemens PLC simulator and processor, it gets the job done. Not every machine you run into in manufacturing has the newest PLCs and software. Many will be older versions that are still doing the job.
Let's take a tour of the ladder logic controlling this. We will skip over the rungs covered previously in the beginner lesson. We must focus on our changes to convert to an open line with educational tidbits added. After watching this video, the best approach is to download the project from the lesson page and study the code.
The best practice is to use standard industry naming conventions and tags instead of addresses as much as possible. So, we changed the "Run" tag to "Auto" and replaced addresses with tags. [picture not-best-practice.jpg] Also, each rung with a descriptive rung comment is best practice. As this PLC simulator software does not support that feature, we at least add network comments to help others read through the program.
The first two rungs of Network 7 are an example of creating a one-second pulse if your PLC brand does not already have a more efficient one-second pulse bit like the one the Allen-Bradley PLC brand has...