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    Hydraulic Press project on Neuron M203 - beginner needs help

    Mervis
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    • R
      r3sist @Martin Kudláček last edited by

      @martin-kudláček Very detailed tips, i found the setting immediately. I lost myself while looking for parameters under Variable Browser.

      I applied the transformation, first at Analog Type - > Current, i've set the points just like u said, but...

      Not sure, but 95% that my sensor is dead, cause the PLC Value reading was oscillating between 0.0078 to 0.0106 or something, the exact same reading is shown when there is nothing wired to the AI1.1/AGND on open contacts.

      I will try to check the pressure sensor alone, ordered another new one, and I will post back the results on a new sensor.

      Thanks a lot for help, will come back to this topic after it arrives.

      Martin Kudláček 1 Reply Last reply Reply Quote 0
      • Martin Kudláček
        Martin Kudláček administrators @r3sist last edited by

        Hi @r3sist, did you configure the module? It looks like you still have the AI in the voltage mode, hence the low readings.

        R 2 Replies Last reply Reply Quote 0
        • R
          r3sist @Martin Kudláček last edited by

          Hi @martin-kudláček, yes, i did reconfigure the module, even twice, trying to swap between the sensor's voltage and current output, with the same result.
          New sensor is on the way, i should give some updates tomorrow.

          1 Reply Last reply Reply Quote 0
          • R
            r3sist @Martin Kudláček last edited by

            Im back, got my hands on an used STS ATM/T 0-400bar, 0-10V output. Configured AI1.1 for voltage mode, plugged the sensor into air line, got some readings after the transformation on around 6,3-6,4bar so it seems correct.

            Now when i have the pressure value I should start coding the machine program itself.

            For first i would want and idle menu machine state, use some kind of case instruction to choose between the automatic and manual press mode where:
            In auto, some RO's would stay on until the before set pressure is met and until limit switches arent tripped.
            Where in manual, no more than 400bars and also to the min/max limit switch positions.

            Could you guys guide me or show some .st examples? I've no idea on how to start it right.

            Also is there a way to connect a simple display to neuron, and also program plc to output for example the A1.1 value?
            I know there is a full hmi panel available, but I would prefer something simple, + / - using DI's, and simple lcd/segment display for it, so an operator could adjust the set pressure for auto mode easily.

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            • J
              josar last edited by

              Hi @r3sist,
              any progress with your project? Very interesting.

              R 1 Reply Last reply Reply Quote 0
              • R
                r3sist @josar last edited by

                @josar Yes, we have a lot of leaking problems at the moment, but its almost finished. Still trying to figure out something more basic for HMI than a weintek panel. I will post the updates with some pictures soon, gonna take about 2 weeks I hope.

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                • R
                  r3sist last edited by

                  So we got most of the leaking solved, time came to code the auto cycle.
                  While coding manal valve closing/openings on button presses was easy, this is where i began to struggle.
                  I followed a guide which was based on a TwinCat 3, but obviously things are different between IDE's.
                  What i would like to know is to how to properly init and call a simple timer and r_trig function block in mervis. Does it have to be manually added into the main.fbd, then called properly from main.st for example? Or can i just declare it in .st which would seem more convenient for me.

                  VAR
                  // timers
                  fbStartautotimer:TON;
                  // triggers
                      fbAutoInit_RTRIG:R_TRIG;
                      fbAutoOff_RTRIG:R_TRIG;
                      fbCycle_RTRIG:R_TRIG;
                      fbZeropos_RTRIG:R_TRIG;
                  END_VAR
                  

                  Also im not sure if the code below will work even if I call the function blocks properly.

                  // auto cycle
                  
                  // button mapping
                  hw.$Neuron M203_DI2.10$:= bManualMode;
                  hw.$Neuron M203_DI2.11$:= bAutoMode;
                  hw.$Neuron M203_DI2.12$:= bAutoEjectorMode;
                  // pressure setpoint and scaling
                  iPressure:= REAL_TO_INT(hw.$Neuron M203_AI1.01$);
                  iPressure_setpoint:= 200;
                  fbAutoInit_RTRIG(clk:=bAutoCycleOn);
                  fbAutoOff_RTRIG(clk:=bAutoCycleOff);
                  
                  IF bAutoMode & fbAutoInit_RTRIG.Q AND NOT fbAutoOff_RTRIG.Q THEN
                      bPumpOn:= TRUE;
                      iState:= 10;
                  ELSE
                      bPumpOff:= TRUE;    
                      iState:= 0;
                  END_IF;
                  CASE iState OF 
                      10:
                      // timer init to let the pump run well
                      fbStartautotimer(IN:bPumpOn,PT:T#2s);
                      IF fbStartautotimer.Q THEN
                          fbStartautotimer(IN:=FALSE);
                      END_IF;
                      fbCycle_RTRIG(clk:=fbStartautotimer.Q);
                      IF fbCycletrigger_RTRIG.Q THEN
                      iState:= 20;
                      sCurrentCycleState:= "Pressing cycle start";
                      END_IF;
                      20:
                      IF iPressure <= iPressure_setpoint AND NOT bLimitswitch2 & fbAutoOff_RTRIG.Q THEN
                      bTableDown_valve:= TRUE;
                      sCurrentCycleState:= "Pressing to the pressure setpoint";
                      iState:= 30;
                      ELSE
                      bTableDown_valve:= FALSE;
                      sCurrentCycleState:= "Cycle stopped, reset";
                      END_IF;
                      30:
                      // expression cycle completed, move the table upwards to 0 position
                      fbZeropos_RTRIG(clk:=iState:=30);
                      IF fbZeropos_RTRIG.Q AND NOT bLimitswitch3 & fbAutoOff_RTRIG.Q THEN
                      bTableUp_valve:= TRUE;
                      iTotalAutoCycles:= iTotalAutoCycles +1;
                      sCurrentCycleState:= "Zeroing table, cycle end";
                      END_IF;
                  END_CASE;
                  

                  I would appreciate a helping hand on this one.

                  Also wondering if this: https://www.waveshare.com/wiki/3.5inch_HDMI_LCD

                  can be hooked up to display the pressure? And assign some leftover DI's for +/- ?

                  1 Reply Last reply Reply Quote 0
                  • T
                    tomas_hora administrators last edited by

                    If you want to call a function(or FB) in a ST, you can create aditional program in ST and call the FB from there.

                    The display however is a HDMI and cannot be hooked to any DIs.

                    1 Reply Last reply Reply Quote 0
                    • J
                      jaroslav_sobota last edited by

                      I guess that @r3sist was trying to cover two separate topics:

                      • using the 3.5" screen as local HMI (or operator screen, depending on the preferred terminology)
                      • using DIs to manipulate some variable(s) in the algorithm, e.g. maximum and minimum for pressure

                      Am I right?

                      Jaroslav

                      R 1 Reply Last reply Reply Quote 0
                      • R
                        r3sist @jaroslav_sobota last edited by

                        @jaroslav_sobota
                        Yes exactly. I just need anything to notify the operator directly on the machine about current pressure , and let him adjust this one pressure setpoint variable. It could even be a segment lcd.

                        T J 2 Replies Last reply Reply Quote 0
                        • T
                          tomas_hora administrators @r3sist last edited by

                          @r3sist thanks for clarification.

                          The best would be to setup a HMI terminal like this one https://www.unipi.technology/weintek-mt8051ip-p198?categoryId=29

                          Hooking buttons to DIs would be OK, but you would have to figure out the display since Neuron do not have native support for HDMI or I2C displays.

                          1 Reply Last reply Reply Quote 0
                          • J
                            jaroslav_sobota @r3sist last edited by

                            @r3sist said in Hydraulic Press project on Neuron M203 - beginner needs help:

                            I just need anything to notify the operator directly on the machine about current pressure , and let him adjust this one pressure setpoint variable. It could even be a segment lcd.

                            If segment LCD is all you need, maybe something like this could do the trick:
                            https://en.papouch.com/tds-rs485-7-segment-led-display-p1922/

                            You can connect it via RS485 and communicate using Modbus RTU.

                            R 1 Reply Last reply Reply Quote 0
                            • R
                              r3sist @jaroslav_sobota last edited by

                              @jaroslav_sobota said in Hydraulic Press project on Neuron M203 - beginner needs help:

                              If segment LCD is all you need, maybe something like this could do the trick:
                              https://en.papouch.com/tds-rs485-7-segment-led-display-p1922/

                              You can connect it via RS485 and communicate using Modbus RTU.

                              Oh, thanks, I was totally unaware of displays over RS485. Yes, this should work.
                              Going to look for a suitable device then, and post updates here.

                              1 Reply Last reply Reply Quote 0
                              • R
                                r3sist last edited by r3sist

                                I finally convinced my boss, and we went with Weintek MT8051iP.
                                Unfortunately i am not able to make any progress with automatic work cycle other than getting function blocks to work at last. Although nothing happens when i press fbAutoCycleOn.

                                Also i wanted to make things easier for me and tried to rename generated variable names for Neuron I/O, but i think the way I did it is completely wrong as I've ran into random troubles.
                                At first i tried something like this :

                                hw.$Neuron M203_RO_2.01_w$:= bPumpOn;
                                

                                But it didnt work, neither for RO or DI's.

                                iPressure:= REAL_TO_INT(hw.$Neuron M203_AI_1.01$);
                                iPressure_setpoint:=200;
                                IF iPressure >= iPressure_setpoint THEN
                                xPressureReached:= TRUE;
                                ELSE
                                xPressureReached:= FALSE;
                                END_IF;
                                
                                (*// relay outputs binding
                                
                                // down valve
                                IF bTableDown_valve THEN
                                hw.$Neuron M203_RO_2.01_w$:= TRUE;
                                ELSE
                                hw.$Neuron M203_RO_2.01_w$:= FALSE;
                                END_IF;
                                // up valve
                                IF bTableUp_valve THEN
                                hw.$Neuron M203_RO_2.02_w$:= TRUE;
                                ELSE
                                hw.$Neuron M203_RO_2.02_w$:= FALSE;
                                END_IF;
                                // bot down valve
                                IF bBottomTableDown_valve THEN
                                hw.$Neuron M203_RO_2.03_w$:= TRUE;
                                ELSE
                                hw.$Neuron M203_RO_2.03_w$:= FALSE;
                                END_IF;
                                // bot up valve
                                IF bBottomTableUp_valve THEN
                                hw.$Neuron M203_RO_2.04_w$:= TRUE;
                                ELSE
                                hw.$Neuron M203_RO_2.04_w$:= FALSE;
                                END_IF;
                                // high pressure
                                IF bHighPressure_valve THEN
                                hw.$Neuron M203_RO_2.05_w$:= TRUE;
                                ELSE
                                hw.$Neuron M203_RO_2.05_w$:= FALSE;
                                END_IF;
                                // pump 
                                IF bPumpOn THEN
                                hw.$Neuron M203_RO_2.06_w$:= TRUE;
                                ELSE
                                hw.$Neuron M203_RO_2.06_w$:= FALSE;
                                END_IF;
                                
                                // input assignment
                                
                                // manual
                                IF hw.$Neuron M203_DI_2.10$ THEN
                                bManualMode:= TRUE;
                                ELSE
                                bManualMode:= FALSE;
                                END_IF;
                                // auto
                                IF hw.$Neuron M203_DI_2.11$ THEN
                                bAutoMode:= TRUE;
                                ELSE
                                bAutoMode:= FALSE;
                                END_IF;
                                // autoeject
                                IF hw.$Neuron M203_DI_2.12$ THEN
                                bAutoEjectorMode:= TRUE;
                                ELSE
                                bAutoEjectorMode:= FALSE;
                                END_IF;
                                // Limit up
                                IF hw.$Neuron M203_DI_1.01$ THEN
                                bLimitTableZero:= TRUE;
                                ELSE
                                bLimitTableZero:= FALSE;
                                END_IF;
                                // Limit bot up
                                IF hw.$Neuron M203_DI_1.02$ THEN
                                bLimitBottomTableUp:= TRUE;
                                ELSE
                                bLimitBottomTableUp:= FALSE;
                                END_IF;
                                // Limit bot down
                                IF hw.$Neuron M203_DI_1.03$ THEN
                                bLimitBottomTableDown:= TRUE;
                                ELSE
                                bLimitBottomTableDown:= FALSE;
                                END_IF;
                                // Pump on
                                IF hw.$Neuron M203_DI_2.01$ THEN
                                bPumpOn_button:= TRUE;
                                ELSE
                                bPumpOn_button:= FALSE;
                                END_IF;
                                // Pump off
                                IF hw.$Neuron M203_DI_2.02$ THEN
                                bPumpOff_button:= TRUE;
                                ELSE
                                bPumpOff_button:= FALSE;
                                END_IF;
                                // Table down
                                IF hw.$Neuron M203_DI_2.03$ THEN
                                bTableDown_button:= TRUE;
                                ELSE
                                bTableDown_button:= FALSE;
                                bTableDown_valve:= FALSE;
                                END_IF;
                                // Table up
                                IF hw.$Neuron M203_DI_2.04$ THEN
                                bTableUp_button:= TRUE;
                                ELSE
                                bTableUp_button:= FALSE;
                                bTableUp_valve:= FALSE;
                                END_IF;
                                // Bot table up
                                IF hw.$Neuron M203_DI_2.05$ THEN
                                bBottomTableUp_button:= TRUE;
                                ELSE
                                bBottomTableUp_button:= FALSE;
                                END_IF;
                                // Bot table down
                                IF hw.$Neuron M203_DI_2.06$ THEN
                                bBottomTableDown_button:= TRUE;
                                ELSE
                                bBottomTableDown_button:= FALSE;
                                END_IF;
                                // Auto on
                                IF hw.$Neuron M203_DI_2.07$ THEN
                                bAutoCycleOn:= TRUE;
                                ELSE
                                bAutoCycleOn:= FALSE;
                                END_IF;
                                // Auto off
                                IF hw.$Neuron M203_DI_2.08$ THEN
                                bAutoCycleOff:= TRUE;
                                ELSE
                                bAutoCycleOff:= FALSE;
                                END_IF;
                                // Zero
                                IF hw.$Neuron M203_DI_2.09$ THEN
                                bZeroTable_button:= TRUE;
                                ELSE
                                bZeroTable_button:= FALSE;
                                END_IF;
                                

                                So right after this I have these IF's :

                                // table up
                                
                                IF bTableUp_button = TRUE AND NOT bLimitTableZero THEN
                                bTableUp_valve:=TRUE;
                                ELSE
                                bTableUp_valve:=FALSE;
                                END_IF;
                                
                                // table down
                                
                                IF bTableDown_button = TRUE AND NOT xPressureReached THEN
                                bTableDown_valve:=TRUE;
                                ELSE
                                bTableDown_valve:=FALSE;
                                END_IF;
                                
                                // ejector down
                                
                                IF bBottomTableDown_button = TRUE &
                                bLimitBottomTableDown = FALSE &
                                bManualMode = TRUE THEN
                                bBottomTableDown_valve:=TRUE;
                                ELSE
                                bBottomTableDown_valve:= FALSE;
                                END_IF;
                                
                                // ejector up
                                
                                IF bBottomTableUp_button = TRUE &
                                bLimitBottomTableUp = FALSE & 
                                bManualMode = TRUE THEN
                                bBottomTableUp_valve:=TRUE;
                                ELSE
                                bBottomTableUp_valve:=FALSE;
                                END_IF;
                                

                                ///

                                fbAutoInit_RTRIG(CLK:=bAutoCycleOn);
                                fbAutoOff_RTRIG(CLK:=bAutoCycleOff);
                                
                                IF  fbAutoInit_RTRIG.Q THEN
                                    xPumpStart:= TRUE;
                                    iState:= 10;
                                ELSE
                                    xPumpStart:= FALSE;    
                                END_IF;
                                
                                CASE iState OF 
                                    10:
                                    // timer init to let the pump run well
                                    fbStartautotimer(IN:=xPumpStart,PT:=iPumpTimeDelay);
                                    IF fbStartautotimer.Q THEN
                                        fbStartautotimer(IN:=FALSE);
                                    END_IF;
                                    fbCycle_RTRIG(clk:=fbStartautotimer.Q);
                                    IF fbCycle_RTRIG.Q THEN
                                    sCurrentCycleState:= "Pressing cycle start";
                                    END_IF;
                                    IF bLimitTableZero = FALSE THEN
                                    bTableUp_valve:= TRUE;
                                    END_IF;
                                    iState:= 20;
                                    20:
                                    IF iPressure <= iPressure_setpoint AND NOT fbAutoOff_RTRIG.Q AND bLimitBottomTableDown THEN
                                    bTableDown_valve:= TRUE;
                                    sCurrentCycleState:= "Pressing to the pressure setpoint";
                                    xAutoZeroPos:= TRUE;
                                    ELSE
                                    bTableDown_valve:= FALSE;
                                    sCurrentCycleState:= "Cycle stopped, reset";
                                    END_IF;
                                    iState:= 30;
                                    30:
                                    // expression cycle completed, move the table upwards to 0 position
                                    fbZeropos_RTRIG(clk:=xAutoZeroPos);
                                    IF fbZeropos_RTRIG.Q AND NOT bLimitTableZero & fbAutoOff_RTRIG.Q THEN
                                    bTableUp_valve:= TRUE;
                                    iTotalAutoCycles:= iTotalAutoCycles +1;
                                    sCurrentCycleState:= "Zeroing table, cycle end";
                                    END_IF;
                                END_CASE;
                                

                                And im totally clueless about what's wrong. I also should point out that i have all that code in one main .st file. Should i divide functions for manual operation and automatic cycle into another .st? Set individual tasks for them?

                                Any help or tips on this would be very appreciated. Im basically out of ideas and my knowledge on PLC programming is narrow.

                                Oh of course Mervis shows no errors. I can upload the project if someone is willing to take a look.

                                Martin Kudláček 1 Reply Last reply Reply Quote 0
                                • Martin Kudláček
                                  Martin Kudláček administrators @r3sist last edited by

                                  Hi @r3sist,
                                  the:

                                  IF bPumpOn THEN
                                  hw.$Neuron M203_RO_2.06_w$:= TRUE;
                                  ELSE
                                  hw.$Neuron M203_RO_2.06_w$:= FALSE;
                                  END_IF;
                                  

                                  is exactly the same as this:

                                  hw.$Neuron M203_RO_2.06_w$:= bPumpOn;
                                  

                                  If there is no syntactic error, which would be detected upon MervisIDE Build, then there is error in the program itself. Try uploading it here or sending it to support@unipi.technology. Please, include a VERY detailed description of the real process, not the itself program. It will help find the real issue.

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