21.08.2017

"Kick off" of the project "Flamizza". First discussion with teacher Mr. Löser and Mr. Musielack. The dates for the "Xplore" projects were discussed. Afterwards, all pupils were allowed to start the workshops with the projects. The remaining time on this day was used by us to assemble the system and to record the current "actual" condition. The first ideas for the expansion of the plant were sketched and discussed. In addition, I have read into the project documentation of last year "PizzaBot".

28.08.2017

On this day I took care of the "Fanuc" control. The robot system showed various errors. The two buffer batteries in the robot were discharged and the measuring systems of the robot had lost the position data. We have passed on the names of the batteries to Mr. Musielack. He wants us to get replacement batteries by next week. Furthermore, I have read into the documentation of the robot to find out how the "mastering" of the robot system works and what is to be observed. Unfortunately, I could not go on at this point, because I need the new buffer batteries. The remaining time I used to come to the existing SPS online. After the interface was set correctly, communication also worked.

04.09.2017

The site has been online since this weekend and there are still a few subtleties to edit. The first time was again discussed and planned in the team the further course. Next week, the task booklet has to be handed out. All ideas for the plant have to be described in detail. The old project was integrated into the PLC. The old function could be produced with the conveyor belt and magazine. The robot does not have buffer buffers and could not be further processed today.

11.09.2017

Today we have our first edition of the Dedicationfinished.Mr. Wohlfahrt from the company SEW was present today and hasfor us personally took time to ask us personally about the drivesto answer. After this discussion the conversion of the dough magazine to aServomotor as this is more suitable for the planned process. Withthe servo can be positioned precisely.

18.09.2017

The batteries for the robot are there and today we could
use the time to start the robot. This includes the "mastering" of the
Robot. This means that all axes are manually moved to the zero mark and the
Measuring system is reset to zero position. Furthermore, the
Order list for Phoenix Contact completed and handed over to Mr. Musielack.

02.10.2017-13.10.2017 (autumn holidays)

About the autumn holidays I have been with the
Final documentation for the project "Flamizza 4.0". It has
I am because of the formatting and structure of the document to the documentation
of the previous year.
Furthermore, I wanted to try out how the communication
between the Visu + and the PC Worx. To this I already have
a project for the visualization started and I first noted down variables
which are important for the ordering information. After the holidays remains to be checked
whether via an "OPC Server" on the hardware PLC the variable communication
can take place.
According to the manual for the software "Visu +" it is possible
Network communications. Thus it would be a possibility over one
Type "server" the visualization can also be displayed on the mobile phone or tablet.
This should also be checked after the holidays during the course of the project work.

16.10.2017

First day after the holidays. Today I wanted to get around that
Communication via an OCP server. For this I have the first versions
from our PLC program and visualization surface used for the
Variables which are declared as OPC variables in the PLC program
Visu + surface.
An OPC server must be used in the OPC Configurator program
, where the communication settings of the PLC are stored.
The OPC Test Client program can be used to monitor the variables used
become.

23.10.2017

Mr. Wohlfart from the company SEW was in the house again today.
He took the time to talk in detail about the magazine again. aim
it is the 6 existing levels on the magazine continue to use. It should
3 for pizza dough and 3 for flame cake dough. To achieve this
we need a drive with the possibility to position exactly.
We came to the conclusion that the current drive at the
Plant remains blocked. We get another external positioner
to attach this to the axle and to take up the turns and to
to process. Furthermore, the inverter must be rebuilt because of the current
has no connection options for an external positioner.

06.11.2017

I took the wireless module from Phönix Contact in today
Business. With the module the Wlan is switched off in the factory condition and must over a
Software from Phönix Contact Commissioning. The wlan had to
Module get a matching IP address and in the network of our plant
to get integrated.

After the wifi was switched on you could also with the
Laptop access the module. This must be the network settings
the network card can be set to the IP address and subnet mask. Well, you can
Wlan on the Visu + panel and the PLC are accessed.

Also the access with the mobile phone over the Visu + mobile App of
PhoenixContact could be tried. The first process pages of the
We could already show visualization on the smartphone.

13.11.2017

After I am at school, but mainly at home
I was able to work on the program "Visu +" and "PCWorx" today
Day the prepared visualization project and the first test program of the SPS
into the controls. The PLC program was after compiling the
Project once many mistakes. I had to do this one by one
locate and fix. Only after the mistakes were all eliminated I could
import the project. Warnings can also be made at a later date
be resolved.
With the OPC configurator, I was able to create a new OPC server
and I have selected the ILC 350 PN controller. This can be done with
the OPC Test Client all variables with the property "OPC" in the PLC program
is selected is read.
These OPC variables I had in the Visu + project with the appropriate
Link buttons. Unfortunately, today I have the following for a very long time
Fighting Problem: When I use the Visu + project on my laptop as a simulation
I could run it after pressing individual buttons
Observe variables in the PLC. Once I have the project on the existing HMI
Device, it no longer works to handle these variables in the PLC
put. After many attempts to fix the error I could not find a solution
for the problem.
At the end of this project day I have Mr. Stephan
helped to dismantle that existing magazine. Mr. Stephan drilled in the middle of the
Wave a 10mm hole, in it we can next install the
Position transmitter of the company SEW begin. We have the missing SEW components
received today from Mr. Müller.

20.11.2017

For the problems with the OPC variables and the Visu + mobile app I found a solution during this day. I was looking for help in an automation forum and got the help of a phoenix contact employee for the problem with the OPC server.

The Visu + keypad used by me is already an older model and the problem for the communication failure was the version difference of the OPC server on the HMI device and my laptop. After I created the OPC server file on the HMI device and linked this file to the Visu + project on my laptop, the visualization and variables communicate via the HMI device.

I was able to find the problem with the Visu + mobile app after a long search. The links of the process pages did not work properly on the phone. Instead of opening a specific process page, the program jumped directly back to the start screen. After replacing the umlauts ä and ü with ae and ue from all file path shortcuts, the operation and connection with the mobile phone also worked.

Later, we presented our project managers Mr. Löser, Mr.
Musielack and Mr. Brandt present our interim presentation. I have made the presentation available for download on the information page.

27.11.2017

After I prepared the step sequence in the PLC program a bit at home, I was able to carry out the first run test today. Today I was only able to carry out the process on the conveyor belt with the current existing document stations. Florian Günster was busy commissioning the new SEW inverter.

I have dealt more closely with the position control of the SEW inverter. To do this, a table positioning must be set up via a Bus field in SEW's Movitool program. All required positions can be created in a table. In each line, a position, start-up ramp and positioning speed must be specified. Over 5 bits, a position must be selected by the PLC. That In order to jump to the table in position 3 in the inverter, the PLC must transmit the following binary code for these 5 bits -> 00011. Via a Word variable, this value is sent to the I / O input word of the inverter by means of a Move command. The Inverter returns a value after reaching this position via a peripheral output word back to the PLC. Here can be checked with a comparison command whether the position was really reached. In order to be able to start a test run, I have excluded all not yet existing stations. After several small mistakes in the
At the end of this day I was able to do a test run for the first time Serve pizza with tomato sauce, cheese, salami and mushrooms.

04.12.2017

Today I took the missing document stations into the program and created the remaining positions for the conveyor belt. The order of a pizza or a Flammkuchen with appropriate ingredients was thus tested. A "dry test run" today worked from the beginning to the end of the conveyor belt. At the end of the conveyor belt I was able to send the robot the signal that an order is ready. I have set the corresponding output of the robot to the PLC via the hand control unit signal that the order has been picked up by the robot. The conveyor belt
then moves to basic position.

When commissioning the inverter for the magazine, we already had communication problems with the PLC and the inverter last week. Unfortunately, we noticed later that a wrong bus card is installed. Therefore, and Mr. Wohlfart sent another card. We could put these into the inverter today. Afterwards PC Worx recognized the inverter as Profinet device and this could be integrated in the bus configuration.

The rest of the evening I tried with Florian Günster to put the converter of the magazine into operation. This caused problems with table positioning afterwards. The inverter often "loses" its reference position and positions in the wrong direction of Rotation.

11.12.2017

Unfortunately, today I have to fight with an unexpected difficulty. The PC Worx no longer opens my current project and indicates that my project file is faulty. I have tried many things but unfortunately can not open the current state. I got help from a forum and had to wait for the answer first. Thus, today I devoted myself to the remaining tasks without programming activities. I installed in the conveyor control cabinet the relay for the new pump for the creme fraiche mass. Unfortunately, after asking for several sponsors, we haveStill no pump for the creme fraiche mass available. Thus havewe in the team decided to buy this pump and share the costs. At the end of the day, I got an employee from PhoenixContact, because of the problem with the PC Worx project and my helpProgram also worked again with the current state.

18.12.2017

Today I was able to try out the new pump and included it provisionally to test the function. The pump works very well with water and hopefully fulfills the function of the Creme Fraiche mass.
 
Today I installed a limit switch to the drink dispenser of Thomas Dhom. This limit switch checks if a beverage can is in the output. This limit switch is placed on the input card of the robot. Thus, the robot program can query the input and determine whether a can is ready for pickup or not.
 
In addition, we were able to successfully test the magazine today. After Florian Günster finished parameterizing the inverter, we successfully started all 6 positions successfully and were therefore able to carry out the first successful "dry runs" from the magazine to the robot with all paper stations.

21.12.2017 - 11.01.2018 (Weihnachtsferien)

I used the holiday season for the documentation, which we have to hand over on 15.01.2018. These included the general part, the individual documentation and all important attachments.

15.01.2018

Since the Xplore "final video" has to be shot by Saturday, we have tried to make the system functional so that individual videos could be shot. I brought along a few ingredients to try out how the separation of the individual stations worked. The dough is prepared on the plate, as the dough band
not yet implemented. Unfortunately, the tomato station does not distribute the sauce so well. Here it is noticed that the distribution is uneven and too little sauce is promoted.
 
The cheese station worked pretty well right from the start. The bacon bunker indeed singles, but stick the bacon cubes very strong and then clog the holes of the singular. Here we had to cut the bacon a bit more.
 
The salami station works, but the salami slices are too thin and squeezed when pressed out. That's why we had to cut the discs a little bit thicker. But even with a knife, the salami slices are too uneven. The time was a bit crowded and we filmed the stations during the separation and had to cut the video a bit to get a good final video.

22.01.2018

First of all, I had to talk to Mr. Musielack and Mr. Brandt. Then I was able to continue working on the system. The dough sheet was implemented in the system today and I was able to make the limit switch cables from the inverter and the motor brake cable from the inverter still pluggable, so that the parts can also be pulled apart.
 
A limit switch is planned for the output station. For this I have already laid the cable once today. I put the cable on the PLC input and an input from the robot. Thus, the signal can be detected on both systems. The program for the edition of the previous year, I have a little revised. For this I extended a few waiting times and programmed the limit switch on the output. The sequencer first jumps to the next step and moves the output back to the basic position when
Limit switch no longer detects a paper plate with pizza. At the same time the robot does not drive to the output as long as there is still a pizza.

29.01.2018

I fixed and set the limit switch for the output today. The holder for the Creme Fraiche pump has been revised and re-attached. The mirror for sheet metal detection, I have also extended a bit to have a larger adjustment because of the dough sheet.
 
Afterwards I had to take care of the remaining documentary stations.
 
For the salami station I pre-sliced salami slices with a bread slicer to 4mm thick. This is how the singulation works.
 
For the mushroom station, I cut the mushrooms in slices and cut them in half again. This will always fall through a few mushroom pieces when the cylinder opens.
 
The onion station was moved a little backwards and throttled the cylinder movement forward. The onions land well on the middle of the sheet. The onions were pre-cut as half rings. For the optics we use red onions. Since the amount of onions does not seem that much, I've reworked the program and now let the onion cylinder cut 2 times per position.
 
Tobias has enlarged the holes at the bacon station, so that the pieces fall better through the holes, but so that not too many cubes fall through and the distribution works better, I have increased the pulsation time of the cylinder. The conveyor had to be slowed down from position 1 to position 2 for better distribution.
 
At the end of the day I did some backtesting with Florian. For this we baked a pizza and a tarte cake by hand and stopped the baking time to find out the optimal time for the robot program. We have agreed and on 350 degrees heat and 5min and 30sec.
 
As a final functional test, we ordered 2 tarte flambée with bacon and onions to test the automation process from the magazine to the output. The test has been successful, there will only be fine adjustments for the open house next Saturday next Saturday.

01.02.2018

Now that the dough band was fully implemented, the first functional tests were able to start. Unfortunately, there was a problem with the belt speed because the dough belt is driven by the conveyor belt drive. The dough sheet runs a bit slower than the conveyor belt. This quickly led to the problem that the sheet is not always passed clean when transferring both bands. Unfortunately, the positions from the table positioning did not fit anymore.
 
We have chosen a quick solution to this problem. For this purpose, we built the sauce station on the other side of the Bosch profile installed a small cylinder with a sheet metal on the free Bosch profile directly in front of the sauce station. This cylinder automatically moves out as soon as the dough sheet is ready and the sheet with the dough is transferred to the conveyor belt. This cylinder holds the sheet until the conveyor has reached a certain intermediate position. Once this intermediate position has been reached, the cylinder is extended again and all subsequent positions of the document stations are offset to this intermediate position.
 
So we could run the dough for the first time and set up all positions.

02.02.2018

As tomorrow is the presentation day, I came to school with Florian in the morning to test final runs with ingredients.
 
The dough band quickly turned out to be a difficult task. The dough is only minimally rolled. Even after I drove the band 3 times back and forth, the dough has visibly thinned but still not so thin to ensure a baking time in such a short time. Since the time is too short, we decided to prepare the dough on the tin and let the dough band run along.
 
The tomato sauce station was purely a matter of attitude. The cylinder went a bit too low and pulled the dough, so we put the cylinder up a bit. The sauce was too tight, so I set a pump delivery time of 5 seconds.
 
The Creme Fraiche Station did not work as well as it was originally planned. We tried to get the mass as fluid as possible with the help of Creme Fine. But unfortunately the mass spread too badly on the dough. Since we use the same station as for the tomato station, the cylinder which is supposed to distribute the sauces is now too high and now spreads the creme fraiche mass much too thick. This is also due to the significantly thinner Flammkuchenteig. A separate station would have been the better alternative here. Finally, we decided to spread the creme fraiche mass onto the dough and remove the creme fraiche station from the program.
 
We were able to test the remaining stations such as cheese, bacon, onions and salami and are ready for the presentation day.
 
Finally, we tested a complete process with 2 orders to test the automatic operation of the plant and the robot.