I/O & Serial communication
The router, the simulation model and the controllers resident in the Dell and the HP computers “drive” the system. Each computer is alluded to as the first or the second computer depending on the controllers that are resident on each system. The serial communication between each computer and the corresponding machine, whose controller is resident in the computer, is established by the RS 232-C interface. The I/O board communication is effected by means of two PCI-DIO48H I/O boards, each installed on the PC bus of the respective computers.
Material Processor (MP) Interface
Material Handler (MH) Interface
Material Handler/Transporter (MT/MH) Interface
Serial Communication
The serial communication between the computer and the machines is utilized for both input and output functions. A 25pin DBconnector on the HAAS machines and the corresponding ports on the computer enable the NC program to be downloaded onto the machine. Each NC File has a G102 code appended to it at the end of the program that returns the current work coordinates MP controller. This is an indication that the program has been executed on the machine and allows the controller to generate subsequent “action” if any. The parameters for this communication are 115,000 BAUD Rate, even parity, seven data bits, one stop bit, remote flow control on, local flow control off.
I/O Communication
The PCI-DIO48H is a high drive digital I/O board. It has 48 bits organized into two 24 bit groups each group being further sub divided into an 8 bit port a, 8 bit port b and an 8 bit port c that can be further sub divided into separate 4 bit nibbles, port C-HI and C-LO. Each 24-bit group is identified by the prefix to the name of the ports mentioned above as first port or second port. The first ports on the I/O board are configured for sending outputs and the second ports are configured for inputs. The screw terminals and Relay racks have been utilized in series with the I/O boards to enable the boards to transmit and receive both outputs and inputs. The Relay rack is used to power all the LED’s and the relays that are used for the cycle start and the reset plungers. The screw terminal accepts the inputs from the limit switches in the system and into the I/O board. The digital output drivers are 74s244 chips that can sink 64mA and source 15mA. The input buffers are 74LS373 chips and have standard high input impedance of the 74LS series. On power up and reset, all I/O bits are set to the input mode. The board being entirely plug and play, is devoid of any switches or jumpers on it. The board is supported by the Universal Library programming library. The pin assignments on both I/O boards to the outputs and the inputs are specified on Table 1. The input and output signals to and from the I/O boards are transmitted to the individual machines and the buffer locations using 25 conductor wire cables, each of which is connected to the respective machines from the corresponding Hubs, one for each I/O board. The hardware connected to computer 1 and 2 are shown in Tables 2 and 3 respectively.
|
CLASS
|
PORT TYPE
|
FUNCTION
|
SL20
|
VFOE
|
VF3
|
SL20WBF
|
HS1RP
|
KARDEX
|
| MP |
OUT
|
Reset (RST) | 2A0 | 2A2 | 2A4 | 1A0 | 1A2 | |
|
OUT
|
Cycle Start (CS) | 2A1 | 2A3 | 2A5 | 1A1 | 1A3 | ||
|
IN
|
Clear_ok (CO) | 2E5 | 2E6 | 2E7 | 1E0 | 1E1 | ||
| Ports |
IN
|
Move_ok (MO) | 1D4 | 1E2 | 1E4 | 1E3 | ||
| Machine Positions |
OUT
|
LED (P/P_pos) | 2B0 | 2B1 | 2B2 | |||
| Buffer |
OUT
|
LED (P/P_pos) | 2C0, 2C1, 2C2, 2C3 | 1A4, 1A5, 1A6, 1A7 | ||||
|
IN
|
SWITCH (Clear_ok) | 2E1, 2E2, 2E3, 2E4 | 1D0, 1D1, 1D2, 1D3 | |||||
| MTMH |
IN
|
SWITCH (Clear_ok) FOR BUFFER | 1F0, 1F1, 1F2, 1F3 | |||||
|
OUT
|
LED (P/P_pos) FOR BUFFER | 1C4, 1C5, 1C6, 1C7 | ||||||
|
OUT
|
Move_loc | 1C3 | 1C0 | 1C2 | 1C1 | |||
|
OUT
|
PICK | 1B3 | 1B0 | 1B2 | 1B1 | |||
|
OUT
|
PUT | 1B7 | 1B4 | 1B6 | 1B5 | |||
| MH |
OUT
|
P/P_pos | 2C4 | 2C5 | 2C6 | |||
|
OUT
|
PICK | 2A6 | ||||||
|
OUT
|
PUT | 2A7 | ||||||
| Serial Port Assignment | 2COM1 | 2COM3 | 2COM4 | 1COM1 | 1COM3 | 1COM4 |
| Computer 1 | ||||||
| DIRECTION | Port | Pin | Function | SSR RACK | SCREW TERM | Hardware Connected |
| OUT | A1 | 0 | SL20WBF - RST | SSR A1 - 5V RELAY | 12VDC SOLENOID | |
| 1 | SL20WBF - CS | SSR A2 - 5V RELAY | SL20WBF CS BUTTON | |||
| 2 | HS1RP - RST | SSR A3 - 5V RELAY | 12VDC SOLENOID | |||
| 3 | HS1RP - CS | SSR A4 - 5V RELAY | HS1RP CS BUTTON | |||
| 4 | KARDEX - POS11 | SSR A5 - NULL | LED | |||
| 5 | KARDEX - POS12 | SSR A6 - NULL | LED | |||
| 6 | KARDEX - POS13 | SSR A7 - NULL | LED | |||
| 7 | KARDEX - POS14 | SSR A8 - NULL | LED | |||
| OUT | B1 | 0 | MTMH - PICK @ PORT1 (SL20WBF) | SSR A9 - NULL | LED | |
| 1 | MTMH - PICK @ PORT2 (KARDEX) | SSR A10 - NULL | LED | |||
| 2 | MTMH - PICK @ PORT3 (HS1RP) | SSR A11 - NULL | LED | |||
| 3 | MTMH - PICK @ PORT4 (BUFFER) | SSR A12 - NULL | LED | |||
| 4 | MTMH - PUT @ PORT1 (SL20WBF) | SSR A13 - NULL | LED | |||
| 5 | MTMH - PUT @ PORT2 (KARDEX) | SSR A14 - NULL | LED | |||
| 6 | MTMH - PUT @ PORT3 (HS1RP) | SSR A15 - NULL | LED | |||
| 7 | MTMH - PUT @ PORT4 (BUFFER) | SSR A16 - NULL | LED | |||
| OUT | CL1 | 0 | MTMH - MOVE_LOC @ PORT1 (SL20WBF) | SSR A17-5V RELAY | 110VAC BULB - GREEN | |
| 1 | MTMH - MOVE_LOC @ PORT2 (KARDEX) | SSR A18-5V RELAY | 110VAC BULB - BLUE | |||
| 2 | MTMH - MOVE_LOC @ PORT3 (HS1RP) | SSR A19-5V RELAY | 110VAC BULB - YELLOW | |||
| 3 | MTMH - MOVE_LOC @ PORT4 (BUFFER) | SSR A20-5V RELAY | 110VAC BULB - RED | |||
| OUT | CH1 | 0 | MTMH<-->BUFFER - POS1 | SSR A21 - NULL | LED | |
| 1 | MTMH<-->BUFFER - POS2 | SSR A22 - NULL | LED | |||
| 2 | MTMH<-->BUFFER - POS3 | SSR A23 - NULL | LED | |||
| 3 | MTMH<-->BUFFER - POS4 | SSR A24 - NULL | LED | |||
| IN | A2 | 0 | KARDEX - CLEAR_OK @ POS1 | SCRW - #32 | MICROSWITCH | |
| 1 | KARDEX - CLEAR_OK @ POS2 | SCRW - #31 | MICROSWITCH | |||
| 2 | KARDEX - CLEAR_OK @ POS3 | SCRW - #30 | MICROSWITCH | |||
| 3 | KARDEX - CLEAR_OK @ POS4 | SCRW - #29 | MICROSWITCH | |||
| 4 | MTMH - MOVE_OK @ PORT4 (BUFFER) | SCRW - #28 | PUSHBUTTON / MICROSWITCH | |||
| 5 | Not assigned! | |||||
| 6 | Not assigned! | |||||
| 7 | Not assigned! | |||||
| IN | B2 | 0 | SL20WBF - CLEAR_OK | SCRW - #40 | MICROSWITCH/ROLLERSWITCH | |
| 1 | HS1RP - CLEAR_OK | SCRW - #39 | MICROSWITCH/ROLLERSWITCH | |||
| 2 | MTMH - MOVE_OK @ PORT1 (SL20WBF) | SCRW - #38 | PUSHBUTTON/MICROSWITCH | |||
| 3 | MTMH - MOVE_OK @ PORT2 (KARDEX) | SCRW - #37 | PUSHBUTTON/MICROSWITCH | |||
| 4 | MTMH - MOVE_OK @ PORT3 (HS1RP) | SCRW - #36 | PUSHBUTTON/MICROSWITCH | |||
| 5 | Not assigned! | |||||
| 6 | Not assigned! | |||||
| 7 | Not assigned! | |||||
| IN | CL2 | 0 | MTMH<-->BUFFER - CLEAR_OK @ POS1 | SCRW - #48 | MICROSWITCH | |
| 1 | MTMH<-->BUFFER - CLEAR_OK @ POS2 | SCRW - #47 | MICROSWITCH | |||
| 2 | MTMH<-->BUFFER - CLEAR_OK @ POS3 | SCRW - #46 | MICROSWITCH | |||
| 3 | MTMH<-->BUFFER - CLEAR_OK @ POS4 | SCRW - #45 | MICROSWITCH | |||
| IN | CH2 | 0 | Not assigned! | |||
| 1 | Not assigned! | |||||
| 2 | Not assigned! | |||||
| 3 | Not assigned! | |||||
| Computer 2 | ||||||
| DIRECTION | Port | Pin | Function | SSR RACK | SCREW TERM | Hardware Connected |
| OUT | A1 | 0 | SL20 - RST | SSR A1-5V RELAY | 12VDC SOLENOID | |
| 1 | SL20 - CS | SSR A2-5V RELAY | SL20 CS BUTTON | |||
| 2 | VFOE - RST | SSR A3-5V RELAY | 12VDC SOLENOID | |||
| 3 | VFOE - CS | SSR A4-5V RELAY | VFOE CS BUTTON | |||
| 4 | VF3 - RST | SSR A5-5V RELAY | 12VDC SOLENOID | |||
| 5 | VF3 - CS | SSR A6-5V RELAY | VF3 CS BUTTON | |||
| 6 | MHMANUAL - common PICK | SSR A7-NULL | LED | |||
| 7 | MHMANUAL - common PUT | SSR A8-NULL | LED | |||
| OUT | B1 | 0 | MHMANUAL <--> SL20 - POS5 | SSR A9 - NULL | LED | |
| 1 | MHMANUAL <--> VFOE - POS6 | SSR A10 - NULL | LED | |||
| 2 | MHMANUAL <--> VF3 - POS7 | SSR A11 - NULL | LED | |||
| 3 | Not assigned! | |||||
| 4 | Not assigned! | |||||
| 5 | Not assigned! | |||||
| 6 | Not assigned! | |||||
| 7 | Not assigned! | |||||
| OUT | CL1 | 0 | MHMANUAL<-->BUFFER - POS1 | SSR A17 - NULL | LED | |
| 1 | MHMANUAL<-->BUFFER - POS2 | SSR A18 - NULL | LED | |||
| 2 | MHMANUAL<-->BUFFER - POS3 | SSR A19 - NULL | LED | |||
| 3 | MHMANUAL<-->BUFFER - POS4 | SSR A20 - NULL | LED | |||
| OUT | CH1 | 0 | Not assigned! | |||
| 1 | Not assigned! | |||||
| 2 | Not assigned! | |||||
| 3 | Not assigned! | |||||
| IN | A2 | 0 | Not assigned! | |||
| 1 | Not assigned! | |||||
| 2 | Not assigned! | |||||
| 3 | Not assigned! | |||||
| 4 | Not assigned! | |||||
| 5 | Not assigned! | |||||
| 6 | Not assigned! | |||||
| 7 | Not assigned! | |||||
| IN | B2 | 0 | Not assigned! | |||
| 1 | MHMANUAL<-->BUFFER - CLEAR_OK @ POS1 | SCRW-#39 | MICROSWITCH | |||
| 2 | MHMANUAL<-->BUFFER - CLEAR_OK @ POS2 | SCRW-#38 | MICROSWITCH | |||
| 3 | MHMANUAL<-->BUFFER - CLEAR_OK @ POS3 | SCRW-#37 | MICROSWITCH | |||
| 4 | MHMANUAL<-->BUFFER - CLEAR_OK @ POS4 | SCRW-#36 | MICROSWITCH | |||
| 5 | SL20 - CLEAR_OK | SCRW-#35 | MICROSWITCH/ROLLERSWITCH | |||
| 6 | VFOE - CLEAR_OK | SCRW-#34 | MICROSWITCH/ROLLERSWITCH | |||
| 7 | VF3 - CLEAR_OK | SCRW-#33 | MICROSWITCH/ROLLERSWITCH | |||
| IN | CL2 | 0 | Not assigned! | |||
| 1 | Not assigned! | |||||
| 2 | Not assigned! | |||||
| 3 | Not assigned! | |||||
| IN | CH2 | 0 | Not assigned! | |||
| 1 | Not assigned! | |||||
| 2 | Not assigned! | |||||
| 3 | Not assigned! | |||||