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PLC/MES Interface Specification for Yanfeng NA Ver

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PLC/MES Interface Specification for Yanfeng NA Ver PLC/MES Interface Specification For Yanfeng NA Ver. 1.0 Date 2018.09.21 1 / 59 Yanfeng Automotive Interiors North America Design: Stephen Shoup Jatin Sheta Email：[email protected] PLC/MES Interface Specification For Yanfeng NA Ver. 1.0 Date 2018.09.21 2 / 59 Contents Abbreviations ............................................................................................................................................................................ 3 Section 1: Main OB1 .................................................................................................................................................................. 4 Section 2: Badge Security Operation Authorization Levels ....................................................................................................... 7 Section 3: PLC Program Structure ............................................................................................................................................. 8 Section 4: PLC/MES Tags ......................................................................................................................................................... 11 Section 5: PLC Cycle Status Codes/MES Status Codes ............................................................................................................. 13 Section 6: Station MES FC ........................................................................................................................................................ 15 Section 7: Trace Data FC .......................................................................................................................................................... 24 Section 8: Fault Reporting FC .................................................................................................................................................. 28 Section 9: Auto Sequence FC Example .................................................................................................................................... 34 Section 10: Requirements for MES/PLC Connectivity ............................................................................................................. 37 Appendix 1. PLC/MES Flow Chart ............................................................................................................................................ 38 Appendix 2. Traceability Data by Machine Type ..................................................................................................................... 39 Appendix 3. Machine/Process/Operations Data ..................................................................................................................... 52 Appendix 4. PLC/MES Handshake Diagrams ........................................................................................................................... 55 Appendix 5. HMI Screens......................................................................................................................................................... 56 PLC/MES Interface Specification For Yanfeng NA Ver. 1.0 Date 2018.09.21 3 / 59 Abbreviations ERP Enterprise Resource Planning MES Manufacturing Execution System YFAI Yanfeng Automotive Interiors OPC OLE for Process Control, OLE， IMM Injection Molding Machine OEM Original Equipment Manufacturer VW Vibration Welding Machine AOI Rockwell Automation Add on Instruction DB Siemens Programming Data Block FB Siemens Programming Function Block FC Siemens Programming Function Call Andon Shop Floor Management Notification System BC Barcode WinnCC Siemens Human Machine Interface (HMI) OPC UA OPC UA(Unified Architecture),OPC IP Instrument Panel DP Door Plate Cockpit Instrument Panel Assembly Subnet Subset of a Larger Industrial Shop Floor Network Gateway A Router Used to Send Data to Other Networks OP Operation Panel HMI Human Machine Interface PanelView Plus Rockwell Automation Human Machine Interface (HMI) PLC/MES Interface Specification For Yanfeng NA Ver. 1.0 Date 2018.09.21 4 / 59 Section 1: Main OB1 The following rungs are located in the template program’s OB1 block and are required for use for MES/PLC integration. This FB is used to check the communication (heartbeat) between MES and the machine. The heartbeat FB will produce a heartbeat from the station PLC and receive a heartbeat from the MES system. The PLC heartbeat to MES will trigger every 500 milliseconds. The PLC will expect to receive the MES heartbeat signal within every 6 seconds. If 6 seconds expire without receiving the MES heartbeat, a station fault should be triggered along with a fault message on the station HMI. See section 8 MES/PLC Fault Reporting for more information. PLC/MES Interface Specification For Yanfeng NA Ver. 1.0 Date 2018.09.21 5 / 59 Section 1 Main OB1 This network is used to collect the PLC date time and construct a date time string for part history data collection and MES/part status override event time stamping. OEM shall set PLC date time prior to or upon commissioning of the equipment in the YFAI facility. Network used to establish a part status override event in the PLC. Note the rung collects the logged in admin user requesting the event and sends to MES for later analysis if needed. The override AOI works by asking the user to select a number of machine cycles they are requesting to override. A maximum number of 10 are allowed per override event. PLC/MES Interface Specification For Yanfeng NA Ver. 1.0 Date 2018.09.21 6 / 59 Section 1 Main OB1 Rung used to establish a MES override event in the PLC. Note the rung collects the logged in admin user requesting the event in PLC arrays for later analysis if needed. The override AOI works by asking the user to select a number of machine cycles they are requesting to override. A maximum number of 10 are allowed per override event. PLC/MES Interface Specification For Yanfeng NA Ver. 1.0 Date 2018.09.21 7 / 59 Section 2: Badge Security Operation Authorization Levels Describes the use of the employee badge for authorizing machine operation and permissive for changes to machine parameters. HMI Security: Levels of security with auto log-off. Operator level Supervisor Level Maintenance Level Engineering Level Administrative Level Credential Protection Badges One Factor authentication (Badge only) Keyboard password input must be disabled – Badge Only Automatic reset of poke-yoke bypass every hour, start of shift and start of machine. PLC/MES Interface Specification For Yanfeng NA Ver. 1.0 Date 2018.09.21 8 / 59 Section 3: PLC Program Structure MES interface data, traceability data, and machine operation data DBs are shown below. Both machine data and trace data types are comprised of arrays of bools, dints, reals, and strings [25] to accommodate various types of data that may be required to collect. Consult with YFAI to determine which of these data types are going to be required for your equipment and automation cell. PLC/MES Interface Specification For Yanfeng NA Ver. 1.0 Date 2018.09.21 9 / 59 Section 3: PLC Program Structure Note regarding “AutoSequenceFC” and “FaultReportingFC”, are provided to show YFAI expecations with how OEM logic shall incorporate both MES and fault data in the OEM program. OEMs can use the examples provided with the write their own logic incorporating the data types and points shown in the template program however, the “Station MES Logic FC”, “OverridePermissiveFB, “DateTimeToStringFB”, “TraceDataFC” and “PartHistoryFB” are required to be used as shown in subsequent chapters of this document. PLC/MES Interface Specification For Yanfeng NA Ver. 1.0 Date 2018.09.21 10 / 59 Section 3: PLC Program Structure Note the user defined PLC data types: PLC/MES Interface Specification For Yanfeng NA Ver. 1.0 Date 2018.09.21 11 / 59 Section 4: PLC/MES Tags PLC to MES PLC tags used with MES. Tags in yellow are trigger events to MES (i.e. cycle start, part cycle complete, and override active.) Note the User ID is a user defined data type with 5 members as shown below under the “User ID” tag TAG Data Type Description “Interface”.ToMES.MasSerNum/DB1005.DBX0.0 STRING[25] Master Serial Number “Interface”.ToMES.MasPartNum/ DB1005.DBX28.0 STRING[25] Master Part Number “Interface”.ToMES.AuxSerNum/ DB1005.DBX56.0 STRING[25] Auxiliary Serial Number “Interface”.ToMES.AuxPartNum/ DB1005.DBX84.0 STRING[25] Auxiliary Part Number “Interface”.ToMES.MachineID/ DB1005.DBX112.0 STRING[20] Machine ID “Interface”.ToMES.PrevMachineID/ DB1005.DBX134.0 STRING[20] Previous Machine ID “Interface”.ToMES.UserID/ DB1005.DBX278.0 z_User User Data Group “Interface”.ToMES.UserID.Name/ DB1005.DBX278.0 STRING[20] User Name (Part of User Data) “Interface”.ToMES.UserID.BadgeIDNum/ DB1005.DBX300.0 STRING[20] User Badge Number (Part of User Data) “Interface”.ToMES.UserID.DataTime/ DB1005.DBX322.0 STRING[25] Data Time of User Event (Part of User Data) “Interface”.ToMES.UserID.AccesLevel/ DB1005.DBX350.0 DINT User Data Access Level (Part of User Data) “Interface”.ToMES.UserID.Password/ DB1005.DBX354.0 STRING[5] User Data Password (Part of User Data) “Interface”.ToMES.BuildData/ DB1005.DBX156.0 STRING[120] Build Data to Send to MES “Interface”.ToMES.CyclStat/ DB1005.DBX362.0 DINT Part Cycle Status “Interface”.ToMES.MachineErrCode/ DB1005.DBX366.0 DINT Machine Error Code to MES “Interface”.ToMES.DownTimeCode/ DB1005.DBX370.0 DINT Down Time Code to MES “Interface”.ToMES.ReqOKCycleStart/ DB1005.DBX374.0 BOOL Request OK Cycle Start to MES “Interface”.ToMES.StartCyclePermittedACK/ DB1005.DBX374.1 BOOL Start Cycle Permitted
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