hexagon manufacturing solutions final report

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FLEXIBLE 
MANUFACTURING 
SYSTEM PROJECT 
_____________________________________________________________________ 
 
AZHAR NIAZI 
CAYURE CARNEIRO 
DANIEL BREITKREUZ 
JITHIN UTHUP 
KARYTAS LEONEL 
YOGIN DOSHI 
 
 
April, 2015 
Aaron Shatkosky 
PROD1601 
 
 
 
i 
 
 
 
 
Typed by: 
Cayure Carneiro 
& Yogin Doshi 
Date: 
04/19/2015 Hexagon Manufacturing Solutions 
Reviewed by: 
Karytas Leonel 
Date: 
04/20/2015 
 
FLEXIBLE 
MANUFACTURING SYSTEM 
PROJECT 
 
Reviewed by: 
Daniel Breitkreuz 
Date: 
04/20/2015 
Reviewed by: 
Jithin Uthup 
Date: 
04/20/2015 
Approved by: 
Azhar Niazi 
Date: 
04/20/2015 
 
 
 
 
 
 
 
 
 
ii 
 
Table of Contents 
1. Overview ............................................................................................................................... 1 
2. Equipment .............................................................................................................................. 1 
2.1 Process Cell Layout .......................................................................................................... 2 
3. Description of Operation ......................................................................................................... 3 
4. Product Specifications ............................................................................................................ 3 
4.1 Finished Parts Drawings ................................................................................................... 5 
5. Robot Documentation ............................................................................................................. 6 
5.1 Methodology ..................................................................................................................... 6 
5.2.1 Station # 1 Robot ....................................................................................................... 7 
5.2.2 Station # 2 Robot ....................................................................................................... 8 
5.2.3 Handshaking Process ...............................................................................................10 
5.3 Cell layout ........................................................................................................................11 
5.4 Point location table ..........................................................................................................12 
5.6 Troubleshooting ...............................................................................................................13 
6. PLC Documentation ..............................................................................................................14 
6.1 Methodology ....................................................................................................................14 
6.2 Flowchart .........................................................................................................................15 
6.4 Troubleshooting ...............................................................................................................18 
7. AS/RS Documentation ..........................................................................................................20 
7.1 Methodology ....................................................................................................................20 
7.2 AS/RS Program ...............................................................................................................21 
8. CNC Documentation .............................................................................................................21 
8.1 Troubleshooting ...............................................................................................................21 
9. Grippers and Fixtures Design ................................................................................................22 
9.1 Guidelines for Grippers and Fixture Design .....................................................................22 
9.1 Gripper and Fixture Drawings ..........................................................................................23 
10. Conclusion ..........................................................................................................................24 
Appendix ...................................................................................................................................25 
I/O TABLE .............................................................................................................................25 
Tolerance Table ....................................................................................................................27 
Attachments ..............................................................................................................................28 
 
iii 
 
 
 
 
 
Figure 1 Flexible Manufacturing Cell layout ................................................................................ 2 
Figure 2 Flat Stock ..................................................................................................................... 4 
Figure 3 2 pcs. Of Round Stock ................................................................................................. 4 
Figure 4 Flat Stock after Machining (Left Hand) ......................................................................... 5 
Figure 5 Round Stock #1 after Machining…..................................................................................5 
Figure 6 Round Stock #2 after machining……………………………………………………………..5 
 
 
Table 1: Point Location Table for both station ...........................................................................12 
Table 2 Input Output Table........................................................................................................26 
Table 3 LC10 Fit Table ..............................................................................................................27 
 
 
 
 
 
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1. Overview 
Flexible Manufacturing Cell consisting of Amatrol 863-AS/RS, Amatrol Programmable 
Control System with Allen Bradly SLC 150 processor, Pegasus 5 axis articulated servo Robots, 
Danford Mill and Lathe Machining Centers, and Amatrol Conveyor, is programmed to make family 
of parts automatically in this project. Given the raw material the FMC is designed to receive the 
materials from AS/RS and go through couple of machining processes to make family of parts. Cell 
also collects the parts from the machining centers and store it back into the AS/RS. Team of 6 
students made this entire project. 
Grippers are designed for the robot arm in accordance to given material. Stationary fixtures 
are also designed to hold the material before the particular machining process. Specific guidelines 
are followed to make the Gripper and Fixture design versatile. 
 
2. Equipment 
Below is the list of equipment: 
- Straight chain conveyor with pallet transfer and return, with 4 pallet unload stations 
- Pallets with pallet fixtures 
- CNC mill Centre 
- CNC lathe Centre 
- Two 5 axis articulated robots 
- Amatrol 863 - AS/RS 
- AB SLC 5/05 PLC Processor 
- PLC with 7 slot chassis 
- RFID readers 
- Relevant hardware and software available in the lab 
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2.1 Process Cell Layout 
1
2
3
4
5
6
7
8
1 – Operator
2 – Control Station
3 – ASRS
4 – Pallet Rack
5 – CNC Mill
6 – Mill Robot
7 – LatheRobot
8 – CNC Lathe
 
Figure 1 Flexible Manufacturing Cell layout 
 
 
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3. Description of Operation 
Using PLC, the pallet will be called from AS/RS according to the user’s necessity. AS/RS put 
the pallet on conveyor. The RFID readers on the conveyor recognizes the pallet and sends the 
signal to PLC to stop the pallet on machining station. On machining station robot gets the signal 
to unload the parts. When unloading is complete and robot is in a safe position, the pallet 
continues to next station for further operation. Meanwhile, the robot sends signal to the vice/chuck 
to get closed and then it moves to a safe position in order to start the machining cycle. A signal is 
sent to CNC machine when the robot gets to safe position. Once machining cycle is complete, 
robot receives a signal from CNC to unload the part. PLC gets a signal to call the pallet from 
AS/RS. Another pallet comes and collects the finished parts. When two machines are in physical 
proximity of each other, appropriate interrupts/interlocks are used to prevent accidental collision 
or damage. The parts are loaded in the pallets on the AS/RS in a separate process outside of this 
project’s scope of work. Another process populate the data tables of the PLC that controls the 
inventory and order information. This can be modified later and is outside of this project’s scope 
of work. 
 
4. Product Specifications 
This system processes the parts from a product family for a two part aluminum assembly. 
Part one is a rectangular extruded flat stock with one large and one small, blind, spot faced hole 
on its broad face. There is a left hand and right hand version of this part. Part two and three are 
cylinders with the end turned down to press fit in the holes of part one. For tolerances see 
Table 2 LC10 Fit. 
The incoming material consists of: 
Part 1: Aluminum Flat Bar ¾” x 2 ½” x 3 ½” LG c/w existing slot. The tolerance on the thickness 
and width of the flat bar is per mill tolerances of Alum 6061-T6. The ends have already been 
milled, so the length has a tolerance of +/- 0.010”. See figure 2. 
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Figure 3 2 pcs. Of Round Stock 
Part 2: Aluminum Round Bar ø1” x 2” LG. The tolerance on the diameter of the round bar is per 
mill tolerances of Alum 6061-T6. The ends have already been faced to a length tolerance of +/- 
0.010”. See figure 1. 
 
 
 
Figure 2 Flat Stock 
 
 
 
 
 
 
 
 
 
 
 
 
 
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Figure 4 Flat Stock after Machining (Left Hand) 
 
 
 
Figure 5 Round Stock #1 after Machining Figure 6 Round Stock #2 after machining 
 
 
4.1 Finished Parts Drawings 
Finished parts drawing are attached at the end of the report. 
Drawings Include: 
- Pin 1 (Sheet – 1) 
- Pin 2 (Sheet – 2) 
- Plate (Sheet – 3) 
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5. Robot Documentation 
5.1 Methodology 
For both station, random teach points are made in order to get the program tested and 
avoid collision among machineries. The points used are listed point location table. 
Once pallet reaches at the machining station PLC sends the signal to relevant robot to 
unload the part from the conveyor. Being more specific, the robot unloads the raw stock from 
pallet at the station and load it into the fixture. Then Robot sends the signal to CNC Machine to 
open the door, once the door is opened CNC sends signal back to robot to put the part into the 
vise/chuck. Robot then puts the part into the vise/chuck. CNC waits to get the signal for closing 
the door and start the operation. Robot sends the signal back to CNC once it reaches to safe 
position. Once the machining process is done Robot gets the signal to get the part from the CNC 
machine. Meanwhile Robot and CNC sends the signal to AS/RS to call for empty pallet. Robot 
then loads the finished part on empty pallet. 
The entire process is programmed to machine one part family which includes: flat stock 
and two round stock. Therefore, the robot loads and unloads the pallet, fixture and CNC with 
pieces for just one assembly. However, we are totally able to do the same for unlimited parts as 
long as we have enough spot on the fixtures and AS/RS. For example, we can use the command 
‘Grwidth’ to measure the distance between the gripper fingers and set a conditions on that. If the 
value obtained is zero then move to the second spot and so on until get some value. Once it is 
done, continue for the next step, loading the fixture and then the CNC. 
 
 
 
 
 
 
 
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5.2.1 Station # 1 Robot 
Start
Wait for PLC
 signal
Pick up parts on 
conveyor
Signal the 
Mill to open 
the door
Load Mill
Is the part 
ready?
A
Unload the CNC
Signal CNC 
to close the 
door
Leave the part on 
fixture
Wait for machining A
Program End
YES
Signal PLC 
to call the 
pallet from 
AS/RS
B
B
Wait for pallet
Is the pallet at the 
station?
Load the 
pallet at the 
station
 NO
Close Vice
Initialize 
Robot
YES
 NO
 
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5.2.2 Station # 2 Robot 
Start
Wait for PLC
 signal
Pick up part 1 
on conveyor
Signal 
the 
Lathe to 
open the 
door
Load Lathe 
w/ Part 2
Is the part 
ready?
A
Unload the 
Lathe
Signal 
Lathe to 
open the 
door
Leave the 
part on fixture
Wait for 
machining
A
NO
YES
Close 
chuck
Initialize 
Robot
Load Fixture
Pick up part 2 
on conveyor
Close 
the door
Pick up part 1 
on fixture
Load Lathe 
w/ Part 1
Wait for 
machining
Close 
chuck
Close 
the door
B
 
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Program End
C
Wait for pallet
Is the pallet at the 
station?
Load the pallet at the 
station
YES
NO
Signal PLC to 
call the pallet 
from ASRS
C
Is the part ready?
B
Unload the Lathe
Signal Lathe 
to open the 
door
NO
YES
Load Conveyor 
part 1
Load Conveyor 
part 2
 
 
 
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5.2.3 Handshaking Process 
Robot Has Come To Safe 
Position
Once The Door Is Opened, CNC 
Highs The Signal To Tell Robot To 
Put The Part Into Vise/Chuck
Robot Sends Signal To CNC To 
Open The Door
Wait For Robot To Come To Safe 
Position
Robot And CNC Send Signal To 
AS/RS And PLC To Call For Empty 
Pallet
Robot Puts The Part Safely Into 
Vise/Chuck and Come Back To 
Safe Position
No Yes
 
 
 
 
 
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5.3 Cell layout 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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5.4 Point location table 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Point Location Table Robot #1 Point Location Table Robot #2 
Point # Name Description Name Description 
0 <home> Robot Home Position <home> Robot Home Position 
1 Point_1 Ready Position Point_1 Ready Position 
2 Point_2 Approach point for conveyor Point_2 Approach point from conveyor PIN 1 
3 Point_3 Pick point for conveyor Point_3 Pick point from conveyor PIN 1 
4 Point_4 Approach point for vise Point_4 Approach point from conveyor PIN 2 
5 Point_5 Pick point for vice Point_5 Pick pointfrom conveyor PIN 2 
6 Point_6 Point clear of CNC Point_6 Approach point from fixture PIN 1 
7 Point_7 Approach point for fixture Point_7 Pick point from fixture PIN1 
8 Point_8 Pick point for fixture Point_8 Approach point from fixture PIN 2 
9 - - Point_9 Pick point from fixture PIN2 
10 - - Point_10 Approach point from the chuck 
11 - - Point_10 Point clear from CNC 
Table 1: Point Location Table for both station 
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5.6 Troubleshooting 
As the robot is in constant communication with the CNC machines, it needs follow all 
requirements. As we did not meet the client requirement to produce two different parts on the mil 
(left hand and right hand), the robot program is written just for one operation. However, it can be 
solved by adding points for the second spot on conveyor and fixture and set the communication 
of the robot and PLC. It means that, the PLC sends a signal to robot inform that the second part 
is ready to be processed. Waiti command keeps the robot for the PLC signal to start the second 
part. It is necessary to add one more line on the robot program in order to notify that second part 
is in process. We use the command “Waiti 2, 1”, which means that the robot proceeds for the 
second operation just after this Input goes high. This signal comes from PLC when the operator 
select the second CNC program. It works exactly the same for both station. Also, we had some 
issues with the points on robot, especially at the second station. We were losing the points on 
every new attempt. This is due the low repeatability of the robots and some crashes suffered by 
it. The robot at the second station was notably twisted. The line highlighted below is to be added 
on the program to separate the operations and make the system flexible. 
 
Call Loadfixture_p1 
 
 Writeo 16, 0 //Open the door and chuck/vice for second operation 
 Waiti 15, 0 //Signal from CNC telling door and chuck opened 
 
Waiti Input_2, on //SIGNAL FROM PLC TO START THE SECOND OPERATION 
 
 
Call Loadcncp2 
 
 Writeo 16, 1 //SEND "PARTE READY" SIGNAL TO CNC CLOSE CHUCK/VICE 
 Waiti 15, 1 //WAIT FOR "CHUCK/VICE" SIGNAL FROM CNC 
 
Release 
Ddmove 2.20,7 
Speed fast 
Pmove Point_11 //Safe posit 
 
 
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6. PLC Documentation 
6.1 Methodology 
Firstly ‘RSLogix 500 English’ has to be configured using ‘RSLinx Classic’ with 
Programmable Logic Controller station. Once the system has been configured the program can 
run on PLC, incorporating ASRS, Conveyor, Robot stations and Machining stations. 
The first step in PLC program is to clear the ASCII buffer so any previous data in register 
is removed. PLC send the signal to ASRS to put the pallet on the conveyor. Note that there is 
different input (Toggle Switch) to call the specific pallet from the ASRS. Pallet is read on First 
RFID and it sends the signal to station #1 stop pin to go high. After First pallet reaches to station 
#1, Pallet positioner will be lifted and signal will be sent to robot #1 to get the part from the 
conveyor. Once the part is taken and robot #1 reaches to safe position, it will send an output 
signal to PLC to low the stop pin so the pallet can move further to Station #2. Pallet is now read 
by second RFID and it sends the signal to station #2 stop pin to go high. After First pallet reaches 
to station #2, pallet positioner is lifted and signal is sent to robot #2 to get the part from the 
conveyor. Once both parts are taken and robot #2 reaches to safe position, it send an input signal 
to PLC to low the stop pin so the pallet can move further to ASRS. Pallet reaches to end of the 
conveyor and once it is read on last RFID, it sends a signal to ASRS to get the part from the 
conveyor. PLC waits for the done signal from both machining and robot stations to put the empty 
pallet on the conveyor. Empty pallet stops at station #1 and then station#2 to get the finished part. 
For Input and Output addressed see the Table 1 Input Output Table. For handshaking between 
robot and cnc see section 5.2.3. PLC program is attached at end of the report. 
 
 
 
 
 
 
 
 
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6.2 Flowchart 
Start PLC & Conveyor
Clear The ASCII Buffer
Wait For The First Pallet To 
Pass First RFID
Read For Pallet At First 
RFID
High First Station Stop Pin
Pallet Has Reached & 
Stopped
Wait For Pallet One To 
Reach At Station One
Get The Signal From Robot 
To Pull Down The Stop Pin 
Back
Wait For The First Pallet To 
Pass Second RFID
Read For Pallet At 
Second RFID
High Second Station Stop 
Pin
Wait For Pallet One To 
Reach At Station Two
Pallet Has Reached & 
Stoped
Follow The Sub Process 
One
Follow The Sub Process 
One
Pull Down The Stop Pin For 
Pallet Station Two Back 
Pallet One Will Go Back To 
ASRS
A
Yes
 No
 Yes
 No
 Yes
Yes
On The Toggle 
Switch To Lift The 
Pallet Station 
Positioner Up
Send The Signal 
To ASRS To Put 
The Part On The 
Conveyor
 
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Robot And CNC Will Give 
The Signal To ASRS To 
Get Empty Pallet On The 
Conveyor
Clear The ASCII Buffer
Wait For The Empty 
Pallet To Pass First RFID
Read For Pallet At 
1st RFID
High First Station Stop Pin
A
Follow The Sub 
Process Two
Wait For The Empty Pallet 
To Pass Second RFID
Read For Pallet At 
2nd RFID
High Second Station Stop 
Pin
Follow The Sub 
Process Two
Signal ASRS To Get The 
Pallet
End PLC Process
 Yes
Wait For Both Machining 
Process To Be Done
 
 
 
 
 
 
 
 
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Signal Robot To Pick The 
Part 
Sub Process One
Pull Down The Stop Pin 
For Pallet Station Back
Wait For Robot To Put 
The Part In Pallet
Pallet Has Reached 
& Stopped
Finished Part Is In 
The Pallet
Sub Process Two
Wait For Pallet One To 
Reach At Station Second
Wait For Robot To Load 
The Part In CNC Machine 
& Come Back To Safe 
Position
Robot Reached To 
Safe Position
Continue To Next Step
 Yes No Yes
 No
 
 Yes
Continue To Next Step
CNC Gets The 
Input To Run 
Specific 
Program
 
 
 
 
 
 
 
 
 
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6.4 Troubleshooting 
In order to make the cell flexible, the computer control system requires to distribute control 
instruction to workstation. Which makes the Cell able to operate even if changes are made in part 
design. That means if the PLC program has specific input to call to run specific CNC program 
then it allows the cell to do production in non-batch mode. Also, if there is change in the design 
of part, then new CNC program can easily be incorporated in the Manufacturing Cell by just adding 
the program in CNC machining station by external source. 
There are few Bit Options in PLC to send the signal to CNC to run the specific program. We 
considered using MOV bit in program to send the signal to CNC to run particular program. So the 
MOV bit output energizes when the specific input is given. MOV bit sends the source number to 
register which is designated for particular machining center. For register and buffer see table 2 
Input Output Table. Excel sheet has to be open in the machining center which has the information 
for the register and the output. RSLinx configures the Rslogix with the process and processor 
connects the Rslogixto machining center or material handling system via RSLinx. And thus 
RSLinx also has to be open in the CNC machine. Once MOV bit output is energized in the PLC 
program it sends the signal through RSLinx to run the program which has number written in the 
Excel file. The program can be corrected by adding the rungs mentioned on next page. 
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7. AS/RS Documentation 
7.1 Methodology 
Automatic Storage and Retrieval System is important integrated part of the Flexible 
Manufacturing Cell. PLC calls AS/RS to put the pallet on conveyor. AS/RS receives the signal 
from PLC and gets the pallet from AS/RS and put it on the conveyor. Note that there is a specific 
input to call specific pallet from the AS/RS. After the machining cycle is done Robot and CNC 
together send the signal to AS/RS and PLC to get the empty pallet. Once AS/RS receives the 
signal it takes the empty pallet from AS/RS and put it into the conveyor. When Pallet reaches to 
end of travel, it is read by RFID and PLC sends the signal to AS/RS to get the pallet from the 
conveyor and load it into the relevant rack. To read the pallet number and make the AS/RS work 
accordingly, program is made into the PLC. 
The AS/RS program is provided along with the excel spread sheet to store the registers and 
buffers. However we followed the procedure bellow to initialize the machine. 
1) Turn the conveyor main power on 
2) Turn the air supplier on 
3) Turn the driver on 
4) Turn the computer on 
5) Open up the RSLinx to set the communication 
6) Open the Excel spread sheet and update it 
7) Open up the Mach 3 
8) Press the main button on AS/RS 
 
After all these steps, the program provided is load onto Mach3 and the cycle is started. Now, 
the AS/RS is able to work and the PLC already gets the Input I: 2/6 (see Table 1 Input Output 
Table). The excel spread sheet is populated automatically and there stores the value of the 
N7:50 and N7:51 register, which means that the ASRS reads the value on there to get the pallet 
informed. 
 
 
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7.2 AS/RS Program 
M106 
M47 
M30 
 
 
 
 
8. CNC Documentation 
For our CNC programs Mastercam was used to create our G-code. The CNC milling 
operation consists of pocket operations. The milling program does the spot face and drilling 
operation on one hole then the same on the next hole. A 3/8” cutter was used. Spindle speed is 
2139. The plunge feed rate is 3.0 in/rev and the milling feed rate is 6.0 in/rev. Depth of cut was 
0.1875” 
The CNC lathe operation consists of a facing, roughing, and finishing operation. A 55 
degree cutter was used. Spindle speed was 2200. The roughing feed rate is 6.0 in/rev and 
finishing feed rate was 3.0 in/rev. Depth of cut is 0.1”. 
CNC documentation is attached at the end of the project. 
8.1 Troubleshooting 
CNC mill speed has to be 2800 rpm. CNC lathe speed has to be 3000 rpm. Lathe feed rates 
adjusted to 9.0 in/rev – 6.0 in/rev. Program must have automatic tool change command, which 
is M06 T05. CNC program for left hand and right part be separate so it can be run on signal it 
machining center gets from the PLC. 
 
 
 
 
 
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9. Grippers and Fixtures Design 
9.1 Guidelines for Grippers and Fixture Design 
The following guidelines have been taken into the consideration while constructing 
grippers for use in two flexible manufacturing work cells. The purpose of the following design 
description is to increase the output of the work cell by avoiding tool changes, grasp multiple part 
orientations with a single gripper, and ensure a secure grasp of part and reduce material. 
 
 Ensure a Secure Grasp of Part 
 
An increase in the speed of the robot is one of the desired effects. Any part has mass, 
and attempting to accelerate this mass as it is moved from the parts feeder to the 
assembly area requires force. This force comes through the grasp the gripper has on 
the part. While it is best to design the gripper to fully encompass the part and not rely 
on friction, this was not practical. In practice, for the best result was observed that it 
would be better used for the plates a straight design in “L” shape, as to the cylinders 
used a design in four opposing “V” grooves. 
 
 Avoid tool change and Grasp Multiple Part orientations with a Single Gripper 
 
Avoid tool changes will decrease cycle time. One approach to avoiding tool changes 
is to design each gripper to handle more than one part orientation. Both of the grippers 
can handle the two orientations required in the work cells. The gripper is able to load 
and unload the conveyor and the CNC. 
 
 Reduce material 
 
In order to reduce the material the fixture was designed with simple slots for the Milling 
parts and holes for the Lathe parts. A countersink was used to help with placing the 
parts inside the fixtures. 
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 Mill fixture locating pin adjustment 
 
The mill fixture had two locating holes to mount onto the stationary pallet. We had an 
issue with one of the holes not aligning properly. We decided to create a slotted hole 
on one of the holes to allow for clearance. We still retained the location we wanted 
because of the other hole. 
 
9.1 Gripper and Fixture Drawings 
Finished Grippers and Fixtures design drawings are attached at the end of the report. 
Drawings include: 
- Gripper for Pins (Sheet – 4) 
- Gripper for Plate (Sheet – 5) 
- Fixture for Plate (Sheet – 6) 
- Fixture for Pins (Sheet – 7) 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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10. Conclusion 
To be concluded the FMS project consists of simple few tasks. However, after trial and error we 
find things that we need to change in order to make cell work in as desired. 
PLC – PLC part is most critical part of the whole project. It works as a liaison between 
AS/RS, Material handling system, Robots, and CNC. Initially we find few errors in program and 
we needed to consult other group for some help. Later we figured out couple of new bits 
(commands) to make correct program. We also find some trouble in configuring our laptops with 
PLC Processor which later with the help of lab coordinator sorted out. 
CNC – The G code for the CNC program is corrected couple of times to get the proper 
alignment on the axis on the mill. Finding the correct sequence of codes to get the lathe to 
handshake properly with the robot take us some time. The mill is easier process then the lathe. 
Robotics – The robot programming since the beginning is considered not to be the most 
difficult part. However, proper CNC’s program is needed for a series of handshaking. Also, the 
points inside the CNC machine required a lot of patience and caution in order to avoid crashes. 
For the lathe, we did not get repeatability to get the points already taught; therefore, we exchanged 
the Lmove command inside the Lathe to Ddmove command. This way, we can sit the part in the 
chuck without problems. 
ASRS – The ASRS is program is provided to us. Except safety procedure we did not have 
to do much in AS/RS. 
Fixture Design – The fixture design was not successful at first. The first design was 
scrapped due to its complexity and overuse of material. We went back to the drawing table and 
made a leaner design. However, the new printed design needed some small changes as well.The slots for the mill parts had to be made larger because the mill parts were fitting too tight. 
Gripper Design – We gave enough brainstorming to gripper design and we ended up going 
with the leaner drawings. 
Overall there were some hiccups in the process but that is the whole point of tackling the 
task as a group. Through troubleshooting we were able to find our errors and connec 
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Appendix 
I/O TABLE 
Input and Outputs 
Pallet Station 1 - Stop Pin O:3/0 
Pallet Station 1 - Restraint Pin O:3/1 
Pallet Station 1 - Pallet Positioner O:3/2 
Pallet Station 2 - Stop Pin O:3/3 
Pallet Station 2 - Restraint Pin O:3/4 
Pallet Station 2 - Pallet Positioner O:3/5 
ASRS M26 (on), M27 (off) I:2/6 
ASRS M28 O:4/7 
Robot Station 2 Input_16 O:3/5 
Robot Station 2 Output_15 I:1/4 
Robot Station 1 Input_15 O:3/2 
Robot Station 1 Output_15 I:1/1 
Toggle 1 I:1/0 
Toggle 2 I:1/1 
Toggle 3 I:1/2 
Toggle 4 I:1/3 
Pallet Station 1 - Proximity I:1/0 
Pallet Station 2 - Proximity I:1/3 
Conveyor End of Travel (EoT) 1:2/5 
Control Box Switch (Toggle) I:5/0 
Control Box Switch (Toggle) I:5/1 
Control Box Switch (Toggle) I:5/2 
Control Box Switch (Toggle) I:5/3 
Control Box Switch (Pushbutton) I:5/6 
Control Box Switch (Pushbutton) I:5/7 
Robot #1 (Mill) Output 1 I:5/12 
Robot #1 (Mill) Output 2 I:5/13 
Robot #2 (Lathe) Output 2 I:5/14 
Robot #2 (Lathe) Output 1 I:5/15 
Control box lamp ASRS and Get Pallet signal O:6/10 
Control box lamp ASRS and Put Pallet signal O:6/11 
Robot #1 (Mill) Input 1 O:6/12 
Robot #2 (Lathe) Input 1 O:6/15 
 
 
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Input and Outputs - Mill/Robot #1 
Robot #1 to Mill Output_16 
M66 (wait for high), 
M76 (wait for low) 
Robot #1 from Mill Input_16 M62 (On), M64 (Off) 
Mill to PLC I:1/15 M63(On) M65(Off) 
Robot #1 to Vice Output 14 
On = Closed, Off = 
Open 
Input and Outputs - Lathe/Robot #2 
Robot #2 to Lathe Output_16 
M66 (wait for high), 
M76 (wait for low) 
Robot #2 from Lathe Input_16 M62 (On), M64 (Off) 
Lathe to PLC I:2/1 M63(On) M65(Off) 
Lathe chuck 
M110 (Open), M111 
(Closed) 
Registers and Buffers 
Mill Program Number N7:49 
Lathe Program Number N7:48 
ASRS Put Pallet Number N7:51 
ASRS Get Pallet Number N7:50 
RFID Buffer Clear Signal (to SLC 5/03) O:4/4 
Table 2 Input Output Table 
 
 
 
 
 
 
 
 
 
 
 
 
 
Hexagon Manufacturing Solutions 
Page 27 of 28 
 
Tolerance Table 
 
Table 3 LC10 Fit Table 
 
Hexagon Manufacturing Solutions 
Page 28 of 28 
 
Attachments 
1. Robot program 
2. PLC program 
3. CNC program 
4. Minutes meetings 
5. Designs 
 
Hexagon Manufacturing Soultions 
Flexible Manufacturing System 
PROD 1601 
Software: Pegasus II Control Software 1.1.3 
 
 
 
 
 
 
 
\ 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Programmer: Cayure Carneiro 
 
 
 
 
 
 Hexagon Manufacturing Solutions 
 
1 
 
 
1. Robot programs 
1.1 Station # 1 Robot 
Global slow 
Global fast 
English 
Pmove <home> 
Release 
Grforce 0.5 
Grwidth 3.5 
Writeo 14, Off 
Writeo 15, Off 
Writeo 16, Off 
Writeo 1,Off 
 
Fast=200 
Slow=40 
 
Label Operation 
 
 Waiti Input_15, On 
If Inp (Input_1) = On then Call Put parts 
 Writeo 1,0 
 
 Call Getparts 
 
 Writeo 15, On //RELEASING THE PALLET 
 Delay 2 
 Writeo 15, Off 
 
 Call Loadfixture 
 
 Writeo 14, Off //OPEN THE VICE 
 Delay 2 //TIME TO OPEN VISE 
 
 Writeo 16,1 //OPEN CNC DOOR 
 Waiti 16,1 //DOOR OPENED 
 
 
 
 
 Hexagon Manufacturing Solutions 
 
2 
 
 Call Loadcnc 
 
 Writeo 14, On //CLOSE VISE 
 
 Writeo 16, 0 //TELLING CNC ROBOT READY, CNC START 
 Waiti 16, 0 //WAIT FOR "CNC DONE" SIGNAL FROM CNC 
 Writeo 14, 0 //OPEN VISE 
 Delay 2 
 
 Call Unloadcnc 
 
Writeo 14,0 //OPEN VISE 
 Delay 2 
 
Pmove Point_4 
Speed Fast 
Pmove Point_6 
Writeo Output_1,On //Input I:5/12 on PLC Call Loadfixture 
 
 Call Loadfixture 
 
Branch Operation 
 
Sub Getparts 
 
//TAKING PART FROM THE CONVEYOR 
Pmove Point_1 //READY POSITION 
Pmove Point_2 //APPROACH POINT FROM THE CONVEYOR 
Speed slow 
Lmove Point_3 //PICK POINT FROM THE CONVEYOR 
Grasp 
Lmove Point_2 
Speed fast 
Pmove Point_1 
 
Return 
 
Sub Loadfixture 
 
Pmove Point_7 //APPROACH POINT FROM THE FIXTURE 
Release 
Pmove Point_6 
 
 Hexagon Manufacturing Solutions 
 
3 
 
Return 
 
 
Sub Loadcnc 
 
 Pmove Point_7 //APPROACH POINT FROM THE FIXTURE 
 Speed Slow 
 Lmove Point_8 //PICK POINT FROM THE FIXTURE 
 Grasp 
 Lmove Point_7 
 Speed Fast 
Pmove Point_4 //MOVE TO APPROACH POINT FOR VISE 
Speed Slow 
Lmove Point_5 //MOVE TO PICK POINT FOR VISE 
Release 
Lmove Point_4 
Speed Fast 
Pmove Point_6 //MOVE TO TP CLEAR OF CNC 
 
Return 
 
Sub Unloadcnc 
 
Pmove Point_4 
Speed Slow 
Lmove Point_5 
Grasp 
 
Return 
 
Sub Putparts 
 
Waiti Input_1, On //PALLET BACK TO GET THE PART READY 
Pmove Point_2 
Speed Slow 
Lmove Point_3 
Release 
Lmove Point_3 
Speed Fast 
Pmove Point_1 
 Writeo Output_15, On //RELEASING THE PALLET 
 Delay 2 
 Writeo Output_15, Off 
 
 Hexagon Manufacturing Solutions 
 
4 
 
 
Branch Operation 
 
Return 
 
 
 
 
1.2 Station # 2 Robot 
Global slow 
Global fast 
English 
Pmove <home> 
Release 
Grforce 0.5 
Grwidth 3.5 
Writeo Output_14, Off 
Writeo 15, Off 
Writeo Output_16, Off 
 
Fast=220 
Slow=40 
 
 
Label Operation 
 
 Waiti Input_16, ON //SIGNAL FROM CONVEYOR, LIFTER IS ON 
If Inp (Input_1) = On then Call Puttingparts 
Writeo Output_1,Off 
 
Call Getparts 
 
 Writeo 15, On //RELEASING THE PALLET 
 Delay 2 
 Writeo 15, Off 
 
 Waiti 15,0 //OPENING CNC DOOR AND CHUCK 
 
Call Loadcncp1 
 
 Writeo 16,1 //SEND "PARTE READY" SIGNAL TO CNC THEN CLOSE CHUCK 
 Waiti 15,1 //WAIT FOR "CHUCK" SIGNAL FROM CNC 
 
 Hexagon Manufacturing Solutions 
 
5 
 
 
Release 
Speed slow 
Ddmove 2.25,7 
Speed fast 
Pmove Point_11 //SAFE POSITION 
 
 Writeo 16,0 //SIGNAL CNC TO CLOSE DOOR AND START OPERATION 
 Waiti 15,0 //WAIT FOR OPERATION DONE AND DOOR OPENED 
 
Delay 2 
Call Unloadcnc 
 
 Writeo 16,1 //SIGNAL TO OPEN THE CHUCK 
 Waiti 15,1 //SIGNAL FROM CNC TELLING THE CHUCK IS OPENED 
 
Ddmove 2.25,7 
Speed fast 
Pmove Point_11 //SAFE POSITION 
 
Call Loadfixture_p1 
 
 Writeo 16,0 //OPEN THE DOOR AND CHUCK FOR SECOND OPERATION 
 Waiti 15,0 //SIGNAL FROM CNC TELLING DOOR AND CHUCK OPENED 
 
Call Loadcncp2 
 
 Writeo 16,1 //SEND "PARTE READY" SIGNAL TO CNC CLOSE CHUCK 
 Waiti 15,1 //WAIT FOR "CHUCK" SIGNAL FROM CNC 
 
Release 
Ddmove 2.25,7 
Speed fast 
Pmove Point_11 //SAFE POSITION 
 
 Writeo 16,0 //SIGNAL CNC TO CLOSE DOOR AND START OPERATION 
 Waiti 15,0 //WAIT FOR OPERATION DONE AND DOOR OPENED 
 
Delay 2 
Call Unloadcnc 
 
 Writeo 16,1 //OPEN THE CHUCK 
 Waiti 15,1 
 
 Hexagon Manufacturing Solutions 
 
6 
 
 
Ddmove 2.25,7 
Speed fastPmove Point_11 //SAFE POSITION 
 
 
//INPUT I:5/15 ON PLC, MAKING THE INPUT_1 GOING HIGH TO CALL THE PALLET BACK 
Writeo Output_1,On 
 
Call Loadfixture_p2 
 
 
Branch Operation 
 
Sub Getparts 
 
Pmove Point_1 //READY POSITION 
Pmove Point_2 //APPROACH POINT FROM THE CONVEYOR 
Speed slow 
Lmove Point_3 //PICK POINT FROM THE CONVEYOR PIN 1 
Grasp 
Lmove Point_2 
Speed fast 
Pmove Point_19 
 
Call Loadfixture_p1 
 
Pmove Point_19 
Pmove Point_4 //APPROACH POINT FROM THE CONVEYOR 
Speed slow 
Lmove Point_5 //PICK POINT FROM THE CONVEYOR PIN 2 
Grasp 
Lmove Point_4 
Speed fast 
 
Call Loadfixture_p2 
 
Return 
 
Sub Loadcncp1 
 
Pmove Point_6 //APPRACH POINT FOR THE FIXTURE PIN 1 
Pmove Point_14 //APPRACH POINT ON THE RIGHT ORIENTATION 
 
 Hexagon Manufacturing Solutions 
 
7 
 
Speed slow 
Lmove Point_13 //PICK POINT FOR THE FIXTURE PIN 1 
Grasp 
Lmove Point_14 
Speed fast 
Pmove Point_11 //AVOIDANCE POINT FROM CNC 
//LOAD CNC MACHINE 
 Pmove Point_10 //APPROACH POINT FOR THE CHUCK 
 Ddmove -2.25,7 
 
Return 
 
Sub Loadcncp2 
 
Pmove Point_8 //APPRACH POINT FOR THE FIXTURE PIN 2 
Pmove Point_16 //APPRACH POINT ON THE RIGHT ORIENTATION 
Speed slow 
Lmove Point_15 //PICK POINT FOR THE FIXTURE PIN 2 
Grasp 
Lmove Point_16 
Pmove Point_11 
Speed fast 
//LOAD CNC MACHINE 
 Pmove Point_10 //APPROACH POINT FOR THE CHUCK 
 Speed slow 
 Ddmove -2.25,7 
 
Return 
 
Sub Unloadcnc 
 
//UNLOAD CNC MACHINE 
Pmove Point_10 //APPROACH POINT FOR THE CHUCK 
Speed slow 
Ddmove -2.25,7 
Grasp 
//OPEN CHUCK 
Return 
 
Sub Loadfixture_p1 
 
Pmove Point_6 //APPROACH POINT FOR THE FIXTURE PIN 1 
Release 
 
 Hexagon Manufacturing Solutions 
 
8 
 
Pmove Point_6 
Pmove Point_12 //AVOIDANCE FOR PINS 
Speed fast 
 
Return 
 
Sub Loadfixture_p2 
 
Pmove Point_19 
Pmove Point_8 //APPRACH POINT FOR THE FIXTURE PIN 2 
Release 
Speed Slow 
Pmove Point_12 
Speed fast 
Return 
 
Sub Puttingparts 
 
Pmove Point_6 //APPRACH POINT FOR THE FIXTURE PIN 1 
Speed slow 
Lmove Point_7 //PICK POINT FOR THE FIXTURE PIN 1 
Grasp 
Lmove Point_6 
Speed fast 
Pmove Point_19 
Pmove Point_2 //APPROACH POINT FROM THE CONVEYOR PIN 1 
Speed slow 
Release 
 
Speed fast 
 
Pmove Point_19 
Pmove Point_8 //APPROACH POINT FOR THE FIXTURE PIN 2 
Speed slow 
Lmove Point_9 //PICK POINT FOR THE FIXTURE PIN 2 
Grasp 
Lmove Point_8 
Pmove Point_19 
Pmove Point_4 //APPROACH POINT FROM THE CONVEYOR PIN 2 
Speed slow 
Lmove Point_5 //PICK POINT FROM THE CONVEYOR PIN 2 
Release 
Lmove Point_4 
 
 Hexagon Manufacturing Solutions 
 
9 
 
Speed fast 
Pmove Point_1 
 Writeo Output_15,On //RELEASING THE PALLET 
 Delay 2 
 Writeo Output_15,Off 
 
Branch Operation 
 
Return 
 
Hexagone Manufacturing Soultions
Flexible Manufacturing System
PROD 1601
Programmer: Karytas Leonel & Yogin Doshi
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Processor Information
Page 1 Wednesday, April 22, 2015 - 21:41:38
 Processor Type: 1747-L553C 5/05 CPU - 64K Mem. OS501 Series C FRN 10 and later
 Processor Name: UNTITLED
 Total Memory Used: *
 Total Memory Left: *
 Program Files: 5
 Data Files: 10
 Program ID: 0
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
I/O Configuration
Page 1 Wednesday, April 22, 2015 - 21:41:38
 0 1747-L553C 5/05 CPU - 64K Mem. OS501 Series C F
 1 1746-IB16 16-Input (SINK) 24 VDC 
 2 1746-IB8 8-Input (SINK) 24 VDC 
 3 1746-OB16 16-Output (TRANS-SRC) 10/50 VDC 
 4 1746-OB8 8-Output (TRANS-SRC) 10/50 VDC 
 5 1746-IB16 16-Input (SINK) 24 VDC 
 6 1746-OW16 16-Output (RLY) 240 VAC 
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Channel Configuration
Page 1 Wednesday, April 22, 2015 - 21:41:38
 GENERAL
 Channel 1 Write Protected: No
 Channel 1 Edit Resource/Owner Timeout(x1 sec): 60
 Channel 1 Passthru Link ID(dec): 2
 Channel 1 Diagnostic File: 0
 Channel 0 Write Protected: No
 Channel 0 Edit Resource/Owner Timeout(x1 sec): 60
 Channel 0 Passthru Link ID(dec): 1
 Channel 0 Current Mode: User
 Channel 0 Mode Change Enabled: No
 Channel 0 Mode Change Attention Character: \1b
 Channel 0 Mode Change System Character: S
 Channel 0 Mode Change User Character: U
 Channel 0 Diagnostic File: 0
 CHANNEL 1 (SYSTEM) - Driver: Ethernet
 Hardware Address: E4:90:69:A0:2D:AA
 IP Address: 192.168.2.100
 Subnet Mask: 255.255.255.0
 Gateway Address: 0.0.0.0
 Default Domain Name: 
 Primary Name Server: 0.0.0.0
 Secondary Name Server 0.0.0.0
 Msg Connection Timeout (x 1mS): 15000
 Msg Reply Timeout (x mS): 3000
 Inactivity Timeout (x Min): 30
 Bootp Enable: No
 Dhcp Enable No
 SNMP Enable: Yes
 HTTP Enable: Yes
 Auto Negotiate Enable: No
 Port Speed Enable: 10 Mbps Half Duplex Forced
 Contact: 
 Location: 
 CHANNEL 0 (SYSTEM) - Driver: DF1 Full Duplex
 Source ID: 0 (decimal)
 Baud: 19200
 Parity: NONE
 Stop Bits: 1
 Control Line : No Handshaking
 Error Detection: CRC
 Embedded Responses: Auto Detect
 Duplicate Packet Detect: Yes
 ACK Timeout(x20 ms): 50
 NAK Retries: 3
 ENQ Retries: 3
 CHANNEL 0 (USER) - Driver: ASCII
 Baud: 9600
 Parity: NONE
 Stop Bits: 2
 Data Bits: 8
 Control Line : No Handshaking
 Delete mode: Ignore
 Echo: No
 XON/XOFF: No
 Termination Character 1: \d
 Termination Character 2: \ff
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Channel Configuration
Page 2 Wednesday, April 22, 2015 - 21:41:38
 Append Character 1: \d
 Append Character 2: \a
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Program File List
Page 1 Wednesday, April 22, 2015 - 21:41:38
Name Number Type Rungs Debug Bytes
[SYSTEM] 0 SYS 0 No 0
 1 SYS 0 No 0
MAIN PROG. 2 LADDER 21 No 694
STATION 1 3 LADDER 7 No 200
STATION 2 4 LADDER 7 No 187
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File List
Page 1 Wednesday, April 22, 2015 - 21:41:38
Name Number Type Scope Debug Words Elements Last
OUTPUT 0 O Global No 9 3 O:2
INPUT 1 I Global No 9 3 I:2
STATUS 2 S Global No 0 83 S:82
BINARY 3 B Global No 11 11 B3:10
TIMER 4 T Global No 12 4 T4:3
COUNTER 5 C Global No 6 2 C5:1
CONTROL 6 R Global No 3 1 R6:0
INTEGER 7 N Global No 52 52 N7:51
FLOAT 8 F Global No 2 1 F8:0
STRING 9 ST Global No 42 1 ST9:0
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
LAD 2 - MAIN PROG. --- Total Rungs in File = 21
Page 1 Wednesday, April 22, 2015 - 21:41:38
S1/15 means that when the fist pass go high
0000
S:1
15
First Pass
I:5
6 
1746-IB16
CLEAR BUFFER OVERIDE
(manually)
T4:3
DN
ACL
Ascii Clear Buffers
Channel 0
Receive Buffer Yes
Transmit Buffer Yes
ACL
 
O:4
4 
1746-OB8
CLEAR BUFFER
RES
C5:0
Reset the counter
after clear the
buffer
RES
C5:1
SETTING DELAY ON COUNTER TO CLEAR THE BUFFER
0001
C5:0
DN
Reset the counter
after clearthe
buffer
T4:3
TT
EN
DN
TON
Timer On Delay
Timer T4:3
Time Base 1.0
Preset 2<
Accum 0<
TON
Read the ASCII buffer
0002
R6:0
EN
ASCII READ CONTROL
EN
DN
ER
ARD
ASCII Read
Channel 0
Dest ST9:0
Control R6:0
String Length 4<
Characters Read 0
 Error 00h
ARD
ASCII READ CONTROL
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
LAD 2 - MAIN PROG. --- Total Rungs in File = 21
Page 2 Wednesday, April 22, 2015 - 21:41:38
0003
R6:0
DN
ASCII READ CONTROL
ACI
String to Integer
Source ST9:0
Dest N7:0
 102<
ACI
ASCII DATA STORAGE
CU
DN
CTU
Count Up
Counter C5:0
Preset 3<
Accum 2<
CTU
Reset the counter
after clear the
buffer
VERIFYING IF THE PALLET IS AT THE END OF THE CONVEYOR. If the value stored on place N7 is greater than 500 means that the pallets
get the end. 5xx
0004
GRT
Greater Than (A>B)
Source A N7:0
 102<
Source B 500
 500<
GRT I:2
5 
1746-IB8
CONV. EOT
SUB
Subtract
Source A N7:0
 102<
Source B 500
 500<
Dest N7:51
 0<
SUB
place to store the
pallet number
L
B3:0
1
RELAY 1
0005
I:2
6 
1746-IB8
ASRS READY
B3:0
1
RELAY 1
I:2
5 
1746-IB8
CONV. EOT
 
O:6
11 
1746-OW16
ASRS SIGNAL LIGHT
 
O:4
7 
1746-OB8
ASRS SIGNAL
M28
0006
I:2
5 
1746-IB8
CONV. EOT
U
B3:0
1
RELAY 1
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
LAD 2 - MAIN PROG. --- Total Rungs in File = 21
Page 3 Wednesday, April 22, 2015 - 21:41:39
0007
LIM
Limit Test
Low Lim 101
 101<
Test N7:0
 102<
High Lim 199
 199<
LIM JSR
Jump To Subroutine
SBR File Number U:3
JSR
U3
0008
LIM
Limit Test
Low Lim 201
 201<
Test N7:0
 102<
High Lim 299
 299<
LIM JSR
Jump To Subroutine
SBR File Number U:4
JSR
U4
GETTING PALLET FROM ASRS
0009
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
I:5
0 
1746-IB16
GET PALLET 1
PAL1
MOV
Move
Source 1
 1
Dest N7:50
 2
MOV
GETTING PALLET FROM ASRS
0010
e
e
e
e
e
e
e
e
e
e
e
I:5
1 
1746-IB16
GET PALLET 2
PAL2
MOV
Move
Source 2
 2
Dest N7:50
 2
MOV
GETTING PALLET FROM ASRS
0011
I:5
2 
1746-IB16
GET_PALLET_3
MOV
Move
Source 3
 3<
Dest N7:50
 2<
MOV
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
LAD 2 - MAIN PROG. --- Total Rungs in File = 21
Page 4 Wednesday, April 22, 2015 - 21:41:39
GETTING PALLET FROM ASRS
0012
I:5
3 
1746-IB16
GET_PALLET_4
MOV
Move
Source 4
 4<
Dest N7:50
 2<
MOV
PRESS THE BUTTON TO MAKE THE ASRS GET THE THE PALLET OR WHEN THE SIGNAL FROM THE ROBOTS ARE GOTTEN
0013
I:5
7 
1746-IB16
PB2
I:5
12 
1746-IB16
OUTPUT COMING FROM
ROBOT #1
I:5
15 
1746-IB16
OUTPUT COMING FROM
ROBOT #2
C5:1
DN
I:2
6 
1746-IB8
ASRS READY
 
O:6
10 
1746-OW16
ASRS_GET_THE_PALLET
0014
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
I:1
15 
1746-IB16
SIGNAL_MILL_TO_PLC
I:2
1 
1746-IB8
SIGNAL_LATHE_TO_PLC
MOV
Move
Source N7:51
 0
Dest N7:50
 2
MOV
 
O:6
12 
1746-OW16
OUTPUT FOR THE ROBOT
#1
 
O:6
15 
1746-OW16
OUTPUT FOR THE ROBOT
#2
0015
e
e
e
e
e
e
e
e
O:6
10 
ASRS_GET_THE_PALLET
CU
DN
CTU
Count Up
Counter C5:1
Preset 2
Accum 0
CTU
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
LAD 2 - MAIN PROG. --- Total Rungs in File = 21
Page 5 Wednesday, April 22, 2015 - 21:41:39
SELECTING PROGRAM FOR THE MILL
0016
e
e
e
e
e
e
e
e
e
I:5
4 
I:5
8 
MOV
Move
Source 1
 ?
Dest N7:49
 ?
MOV
0017
e
e
e
e
e
e
e
e
e
e
e
e
I:5
4 
MOV
Move
Source 2
 ?
Dest N7:49
 ?
MOV
 
O:6
13 
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
LAD 2 - MAIN PROG. --- Total Rungs in File = 21
Page 6 Wednesday, April 22, 2015 - 21:41:39
SELECTING PROGRAM FOR THE LATHE
0018
e
e
e
e
e
e
e
e
e
I:5
5 
I:5
9 
MOV
Move
Source 1
 ?
Dest N7:48
 ?
MOV
0019
e
e
e
e
e
e
e
e
e
e
e
e
I:5
5 
MOV
Move
Source 2
 ?
Dest N7:48
 ?
MOV
 
O:6
14 
0020 END
 
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
LAD 3 - STATION 1 --- Total Rungs in File = 7
Page 1 Wednesday, April 22, 2015 - 21:41:39
0000
SBR
Subroutine
SBR
 
B3:10
1
LIFTING THE GAGE PIN AFTER THE PALLET PASS THROUGH A LIMIT SWITCH
0001
I:1
0 
1746-IB16
TRIGGER
LS1
O:3
0 
1746-OB16
GAGE PIN
T4:2
DN
RESTRAIN PIN
DROP_DELAY
T4:2
TT
RESTRAIN PIN
DROP DELAY
 
O:3
0 
1746-OB16
GAGE PIN
EN
DN
TON
Timer On Delay
Timer T4:0
Time Base 1.0
Preset 2<
Accum 2<
TON
AFTER A NECESSARY TIME, ENERGIZED BY THE LS1, THE RESTRAIN PIN GOES UP IN ORDER TO AVOID A SECOND PALLET
GOES INTO THE STATION.
0002
T4:0
DN
RESTRAIN PIN
RAISE_DELAY
O:3
1 
1746-OB16
RESTRAINT PIN
T4:2
DN
RESTRAIN PIN
DROP_DELAY
 
O:3
1 
1746-OB16
RESTRAINT PIN
EN
DN
TON
Timer On Delay
Timer T4:1
Time Base 1.0
Preset 2<
Accum 2<
TON
RESTRAIN PIN
RAISE DELAY
AFTER TO RESTRAIN PIN GOES UP AND A CERTAIN AMOUNT OF TIME, THE LIFTER HOLDS THE PALLET UP.
0003
O:3
1 
1746-OB16
RESTRAINT PIN
T4:1
DN
POSITIONER TABLE
RAISE DELAY
O:3
2 
1746-OB16
POSITIONER TABLE
T4:2
TT
RESTRAIN PIN
DROP DELAY
 
O:3
2 
1746-OB16
POSITIONER TABLE
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
LAD 3 - STATION 1 --- Total Rungs in File = 7
Page 2 Wednesday, April 22, 2015 - 21:41:39
THEN, THE ROBOT SEND THE SIGNAL OF READY AND THE THE PINS AND THE LIFTER GET OFF
0004
I:1
1 
1746-IB16
ROBOT DONE
I:5
10 
1746-IB16
T4:2
DN
RESTRAIN PIN
DROP_DELAY
EN
DN
TON
Timer On Delay
Timer T4:2
Time Base 1.0
Preset 2<
Accum 0<
TON
RESTRAIN PIN
DROP DELAY
0005
RET
Return
RET
0006 END
 
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
LAD 4 - STATION 2 --- Total Rungs in File = 7
Page 1 Wednesday, April 22, 2015 - 21:41:39
0000
SBR
Subroutine
SBR
 
B3:10
1
LIFTING THE GAGE PIN AFTER THE PALLET PASS THROUGH A LIMIT SWITCH
0001
I:1
3 
1746-IB16
TRIGGER
LS2
O:3
3 
1746-OB16
GAGE PIN
STOP_ST2
T4:2
DN
RESTRAIN PIN
DROP_DELAY
T4:2
TT
RESTRAIN PIN
DROP DELAY
 
O:3
3 
1746-OB16
GAGE PIN
STOP_ST2
EN
DN
TON
Timer On Delay
Timer T4:0
Time Base 1.0
Preset 2<
Accum 2<
TON
AFTER A NECESSARY TIME, ENERGIZED BY THE LS1, THE RESTRAIN PIN GOES UP IN ORDER TO AVOID A SECOND PALLET
GOES INTO THE STATION.
0002
T4:0
DN
RESTRAIN PIN
RAISE_DELAY
O:3
1 
1746-OB16
RESTRAINT PIN
T4:2
DN
RESTRAIN PIN
DROP_DELAY
 
O:3
4 
1746-OB16
RESTRAINT PIN
EN
DN
TON
Timer On Delay
Timer T4:1
Time Base 1.0
Preset 2<
Accum 2<
TON
RESTRAIN PIN
RAISE DELAY
0003
O:3
4 
1746-OB16
RESTRAINT PIN
T4:1
DN
POSITIONER TABLE
RAISE DELAY
T4:2
TT
RESTRAIN PIN
DROP DELAY
 
O:3
5 
1746-OB16
POSITIONER STATION 2
THEN, THE ROBOT SEND THE SIGNAL OF READY AND THE THE PINS AND THE LIFTER GET OFF
0004
I:1
4 
1746-IB16
I:5
11 
1746-IB16
T4:2
DN
RESTRAIN PIN
DROP_DELAY
EN
DN
TON
Timer On Delay
Timer T4:2
Time Base 1.0
Preset 2<
Accum 0<
TON
RESTRAINPIN
DROP DELAY
0005
RET
Return
RET
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
LAD 4 - STATION 2 --- Total Rungs in File = 7
Page 2 Wednesday, April 22, 2015 - 21:41:39
0006 END
 
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File O0 (bin) -- OUTPUT
Page 1 (Radix Binary) Wednesday, April 22, 2015 - 21:41:39
Offset 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 
O:3.0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1746-OB16 - 16-Output (TRANS-SRC) 10/50 VDC
O:4.0 0 0 0 0 0 0 0 0 1746-OB8 - 8-Output (TRANS-SRC) 10/50 VDC
O:6.0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1746-OW16 - 16-Output (RLY) 240 VAC
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File I1 (bin) -- INPUT
Page 1 (Radix Binary) Wednesday, April 22, 2015 - 21:41:39
Offset 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 
I:1.0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1746-IB16 - 16-Input (SINK) 24 VDC
I:2.0 0 1 0 0 0 1 0 0 1746-IB8 - 8-Input (SINK) 24 VDC
I:5.0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1746-IB16 - 16-Input (SINK) 24 VDC
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File S2 (hex) -- STATUS
Page 1 Wednesday, April 22, 2015 - 21:41:39
 Main
 First Pass S:1/15 = No
 Index Register S:24 = 0
 Free Running Clock S:4 = 1100-0100-1110-0111
 Index Across Data Files S:2/3 = No
 CIF Addressing Mode S:2/8 = 0
 Online Edits S:33/11 - S:33/12 = No online edits exist
 Day of the Week S:53L = Tuesday
 DD / MM / YYYY
 Date S:39-37 = 17 / 8 / 2000
 HH : MM : SS
 Time S:40-42 = 4 : 32 : 18
 Proc
 OS Catalog Number S:57 = 501
 OS Series S:58 = C
 OS FRS S:59 = 13
 Processor Catalog Number S:60 = 553
 Processor Series S:61 = C
 Processor FRN S:62 = 5
 Ethernet Daughterboard Series S:9 = 3
 Ethernet Daughterboard FRN S:10 = 54
 User Program Type S:63 = 2049
 User Program Functionality Index S:64 = 125
 User RAM Size S:66 = 64
 OS Memory Size S:66 = 512
 Scan Times
 Maximum (x10 ms) S:22 = 1
 Average (x10 ms) S:23 = 0
 Current (x10 ms) S:3 (low byte) = 0
 Watchdog (x10 ms) S:3 (high byte) = 10
 Last 1ms Scan Time S:35 = 2
 Scan Toggle Bit S:33/9 = 1
 Time Base Selection S:33/13 = 0
 Math
 Math Overflow Selected S:2/14 = 0
 Overflow Trap S:5/0 = 0
 Carry S:0/0 = 0
 Overflow S:0/1 = 0
 Zero Bit S:0/2 = 0
 Sign Bit S:0/3 = 0
 Floating Point Flag Disable S:34/2 = 0
 Math Register (lo word) S:13 = 0
 Math Register (high word) S:14-S:13 = 0
 Math Register (32 Bit) S:14-S:13 = 0
 IO
I/O Interrupt Executing S:32 = 0 Interrrupt Latency Control S:33/8 = 0
Event Interrupt 10 uS Time Stamp S:44 = 0
 I/O Slot Enables: S:11 S:12
0 10 20 30
11111111 11111111 11111111 11111111
 I/O Slot Interrupt Enables: S:27 S:28
0 10 20 30
11111111 11111111 11111111 11111111
 I/O Slot Interrupt Pending: S:25 S:26
0 10 20 30
00000000 00000000 00000000 00000000
 Chan 0
 Processor Mode S:1/0- S:1/4 = Remote Run
 Channel Mode S:33/3 = 0
 Comms Active S:33/4 = 0
 Incoming Cmd Pending S:33/0 = 0
 Msg Reply Pending S:33/1 = 0
 DTR Control Bit S:33/14 = 0
 DTR Force Bit S:33/15 = 0
 Outgoing Msg Cmd Pending S:33/2 = 0
 Comms Servicing Sel S:33/5 = 0
 Msg Servicing Sel S:33/6 = 0
 Modem Lost S:5/14 = 0
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File S2 (hex) -- STATUS
Page 2 Wednesday, April 22, 2015 - 21:41:39
 Chan 1
 Processor Mode S:1/0- S:1/4 = Remote Run
 Comms Active S:1/7 = 1
 Incoming Cmd Pending S:2/5 = 0
 Msg Reply Pending S:2/6 = 0
 DH485 Gateway Disable Bit S:34/0 = 0
 DF1 Gateway Enable Bit S:34/5 = 0
 Outgoing Msg Cmd Pending S:2/7 = 0
 Comms Servicing Sel S:2/15 = 1
 Msg Servicing Sel S:33/7 = 0
 Debug
 Suspend Code S:7 = 0
 Suspend File S:8 = 0
 Compiled For Single Step S:2/4 = Yes
 Fault/Powerdown
 Fault/Powerdown (Rung #) S:20 = 0
 (File #) S:21 = 0
 Test Single Step Breakpoint
 Rung # S:18 = 0
 File # S:19 = 0
 Test Single Step
 Rung # S:16 = 0
 File # S:17 = 2
 Errors
 Fault Override At Power Up S:1/8 = 0
 Startup Protection Fault S:1/9 = 0
 Major Error Halt S:1/13 = 0
 Overflow Trap S:5/0 = 0
 Control Register Error S:5/2 = 0
 Major Error Executing User 
 Fault Rtn. S:5/3 = 0
 M0/M1 Referenced On Disabled 
 Slot S:5/4 = 0
 Battery Low S:5/11 = 0
 Fault/Powerdown (Rung #) S:20 = 0
 (File #) S:21 = 0
 ASCII String Manipulation error S:5/15 = 0
 Fault Routine S:29 = 0
 Major Error S:6 = 0h
 Error Description:
 STI
 Setpoint (x10ms) S:30 = 0
 File Number S:31 = 0
 10 uS Time Stamp S:43 = 0
 Pending Bit S:2/0 = 0
 Enable Bit S:2/1 = 1
 Resolution Select Bit S:2/10 = 0
 Executing Bit S:2/2 = 0
 Overflow Bit S:5/10 = 0
 Lost S:36/9 = 0
 Interrrupt Latency Control S:33/8 = 0
 DII
 Preset S:50 = 0
 Accumulator S:52 = 0
 Pending Bit S:2/11 = 0
 Enable Bit S:2/12 = 1
 Executing Bit S:2/13 = 0
 Reconfiguration Bit S:33/10 = 0
 Overflow Bit S:5/12 = 0
 Lost S:36/8 = 0
 10 uS Time Stamp S:45 = 0
 File Number S:46 = 0
 Slot Number S:47 = 0
 Bit Mask S:48 = 0h
 Compare Value S:49 = 0h
 Return Mask S:51 = 0h
 Last Scan Time (x1 ms) S:55 = 0
 Max Observed Scan Time (x1 ms) S:56 = 0
 Interrrupt Latency Control S:33/8 = 0
 Protection
 Deny Future Access S:1/14 = No
 Mem Module
 Memory Module Loaded On Boot S:5/8 = 0
 Password Mismatch S:5/9 = 0
 Load Memory Module On Memory Error S:1/10 = 0
 Load Memory Module Always S:1/11 = 0
 Load Memory Module and RUN S:1/12 = 0
 Program Compare S:2/9 = 0
 Data File Overwrite Protection Lost S:36/10 = 0
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File S2 (hex) -- STATUS
Page 3 Wednesday, April 22, 2015 - 21:41:39
 Forces
 Forces Enabled S:1/5 = No
 Forces Installed S:1/6 = No
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File B3 (bin) -- BINARY
Page 1 (Radix Binary) Wednesday, April 22, 2015 - 21:41:39
Offset 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 (Symbol) Description 
B3:0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 
B3:1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 
B3:2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 
B3:3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 
B3:4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 
B3:5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 
B3:6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 
B3:7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 
B3:8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 
B3:9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 
B3:10 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File T4 -- TIMER
Page 1 Wednesday, April 22, 2015 - 21:41:39
Offset EN TT DN BASE PRE ACC (Symbol) Description 
T4:0 1 0 1 1.0 sec 2 2 
T4:1 1 0 1 1.0 sec 2 2 RESTRAIN PIN RAISE DELAY 
T4:2 0 0 0 1.0 sec 2 0 RESTRAIN PIN DROP DELAY 
T4:3 0 0 0 1.0 sec 2 0 
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File C5 -- COUNTER
Page 1 Wednesday, April 22, 2015 - 21:41:39
Offset CU CD DN OV UN UA PRE ACC (Symbol) Description 
C5:0 0 0 0 0 0 0 3 2 Reset the counter after clear the buffer 
C5:1 0 0 0 0 0 0 2 0 
HEXAGONMANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File R6 -- CONTROL
Page 1 Wednesday, April 22, 2015 - 21:41:39
Offset EN EU DN EM ER UL IN FD LEN POS (Symbol) Description 
R6:0 1 1 0 0 0 0 1 0 4 0 ASCII READ CONTROL 
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File N7 (dec) -- INTEGER
Page 1 (Radix Decimal) Wednesday, April 22, 2015 - 21:41:39
Offset 0 1 2 3 4 5 6 7 8 9 
N7:0 102 0 0 0 0 0 0 0 0 0 
N7:10 0 0 0 0 0 0 0 0 0 0 
N7:20 0 0 0 0 0 0 0 0 0 0 
N7:30 0 0 0 0 0 0 0 0 0 0 
N7:40 0 0 0 0 0 0 0 0 0 0 
N7:50 2 0 
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File F8 -- FLOAT
Page 1 Wednesday, April 22, 2015 - 21:41:40
Offset 0 1 2 3 4 
F8:0 0 
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File ST9 -- STRING
Page 1 Wednesday, April 22, 2015 - 21:41:40
Offset LEN String Text (Symbol) Description 
ST9:0 4 0102 ASCII DA
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Address/Symbol Database
Page 1 Wednesday, April 22, 2015 - 21:41:40
Address Symbol Scope Description Sym Group Dev. Code ABV
B3:0
B3:0/1 RELAY 1 
B3:0/2
B3:2
B3:2/1
B3:2/2
B3:10/1
C5:0 Reset the counter after clear the buffer 
C5:0/DN
C5:1
C5:1/DN
I:1/0 LS1 Global TRIGGER 
I:1/1 ROBOT DONE 
I:1/2 SIGNAL_LATHE_TO_PLC Global
I:1/3 LS2 Global TRIGGER 
I:1/4
I:1/15 SIGNAL_MILL_TO_PLC 
I:2/1 SIGNAL_LATHE_TO_PLC 
I:2/5 CONV. EOT 
I:2/6 ASRS READY 
I:5/0 PAL1 Global GET PALLET 1 
I:5/1 PAL2 Global GET PALLET 2 
I:5/2 GET_PALLET_3 Global
I:5/3 GET_PALLET_4 Global
I:5/4
I:5/5
I:5/6 CLEAR BUFFER OVERIDE (manually) 
I:5/7 PB2 Global
I:5/8
I:5/9
I:5/10
I:5/11
I:5/12 OUTPUT COMING FROM ROBOT #1 
I:5/14 OUTPUT COMING FROM ROBOT #2 
I:5/15 OUTPUT COMING FROM ROBOT #2 
N7:0
N7:10
N7:11
N7:48
N7:50
N7:51 place to store the pallet number 
O:3/0 GAGE PIN 
O:3/1 RESTRAINT PIN 
O:3/2 POSITIONER TABLE 
O:3/3 STOP_ST2 Global GAGE PIN 
O:3/4 RESTRAINT PIN 
O:3/5 POSITIONER STATION 2 
O:4/4 CLEAR BUFFER 
O:4/7 ASRS SIGNAL M28 
O:4/14 CLEAR BUFFER 5/03 
O:6/10 ASRS_GET_THE_PALLET Global
O:6/11 ASRS SIGNAL LIGHT 
O:6/12 OUTPUT FOR THE ROBOT #1 
O:6/13
O:6/14
O:6/15 OUTPUT FOR THE ROBOT #2 
R6:0 ASCII READ CONTROL 
R6:0/DN
R6:0/EN
S:0 Arithmetic Flags 
S:0/0 Processor Arithmetic Carry Flag 
S:0/1 Processor Arithmetic Underflow/ Overflow Flag 
S:0/2 Processor Arithmetic Zero Flag 
S:0/3 Processor Arithmetic Sign Flag 
S:1 Processor Mode Status/ Control 
S:1/0 Processor Mode Bit 0 
S:1/1 Processor Mode Bit 1 
S:1/2 Processor Mode Bit 2 
S:1/3 Processor Mode Bit 3 
S:1/4 Processor Mode Bit 4 
S:1/5 Forces Enabled 
S:1/6 Forces Present 
S:1/7 Comms Active 
S:1/8 Fault Override at Powerup 
S:1/9 Startup Protection Fault 
S:1/10 Load Memory Module on Memory Error 
S:1/11 Load Memory Module Always 
S:1/12 Load Memory Module and RUN 
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Address/Symbol Database
Page 2 Wednesday, April 22, 2015 - 21:41:40
Address Symbol Scope Description Sym Group Dev. Code ABV
S:1/13 Major Error Halted 
S:1/14 Access Denied 
S:1/15 First Pass 
S:2/0 STI Pending 
S:2/1 STI Enabled 
S:2/2 STI Executing 
S:2/3 Index Addressing File Range 
S:2/4 Saved with Debug Single Step 
S:2/5 DH-485 Incoming Command Pending 
S:2/6 DH-485 Message Reply Pending 
S:2/7 DH-485 Outgoing Message Command Pending 
S:2/15 Comms Servicing Selection 
S:3 Current Scan Time/ Watchdog Scan Time 
S:4 Time Base 
S:5/0 Overflow Trap 
S:5/2 Control Register Error 
S:5/3 Major Err Detected Executing UserFault Routine 
S:5/4 M0-M1 Referenced on Disabled Slot 
S:5/8 Memory Module Boot 
S:5/9 Memory Module Password Mismatch 
S:5/10 STI Overflow 
S:5/11 Battery Low 
S:6 Major Error Fault Code 
S:7 Suspend Code 
S:8 Suspend File 
S:9 Active Nodes 
S:10 Active Nodes 
S:11 I/O Slot Enables 
S:12 I/O Slot Enables 
S:13 Math Register 
S:14 Math Register 
S:15 Node Address/ Baud Rate 
S:16 Debug Single Step Rung 
S:17 Debug Single Step File 
S:18 Debug Single Step Breakpoint Rung 
S:19 Debug Single Step Breakpoint File 
S:20 Debug Fault/ Powerdown Rung 
S:21 Debug Fault/ Powerdown File 
S:22 Maximum Observed Scan Time 
S:23 Average Scan Time 
S:24 Index Register 
S:25 I/O Interrupt Pending 
S:26 I/O Interrupt Pending 
S:27 I/O Interrupt Enabled 
S:28 I/O Interrupt Enabled 
S:29 User Fault Routine File Number 
S:30 STI Setpoint 
S:31 STI File Number 
S:32 I/O Interrupt Executing 
S:33 Extended Proc Status Control Word 
S:33/0 Incoming Command Pending 
S:33/1 Message Reply Pending 
S:33/2 Outgoing Message Command Pending 
S:33/3 Selection Status User/DF1 
S:33/4 Communicat Active 
S:33/5 Communicat Servicing Selection 
S:33/6 Message Servicing Selection Channel 0 
S:33/7 Message Servicing Selection Channel 1 
S:33/8 Interrupt Latency Control Flag 
S:33/9 Scan Toggle Flag 
S:33/10 Discrete Input Interrupt Reconfigur Flag 
S:33/11 Online Edit Status 
S:33/12 Online Edit Status 
S:33/13 Scan Time Timebase Selection 
S:33/14 DTR Control Bit 
S:33/15 DTR Force Bit 
S:34 Pass-thru Disabled 
S:34/0 Pass-Thru Disabled Flag 
S:34/1 DH+ Active Node Table Enable Flag 
S:34/2 Floating Point Math Flag Disable,Fl 
S:35 Last 1 ms Scan Time 
S:36 Extended Minor Error Bits 
S:36/8 DII Lost 
S:36/9 STI Lost 
S:36/10 Memory Module Data File Overwrite Protection 
S:37 Clock Calendar Year 
S:38 Clock Calendar Month 
S:39 Clock Calendar Day 
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Address/Symbol Database
Page 3 Wednesday, April 22, 2015 - 21:41:40
Address Symbol Scope Description Sym Group Dev. Code ABV
S:40 Clock Calendar Hours 
S:41 Clock Calendar Minutes 
S:42 Clock Calendar Seconds 
S:43 STI Interrupt Time 
S:44 I/O Event Interrupt Time 
S:45 DII Interrupt Time 
S:46 Discrete Input Interrupt- File Number 
S:47 Discrete Input Interrupt- Slot Number 
S:48 Discrete Input Interrupt- Bit Mask 
S:49 Discrete Input Interrupt- Compare Value 
S:50 Processor Catalog Number 
S:51 Discrete Input Interrupt- Return Number 
S:52 Discrete Input Interrupt- Accumulat 
S:53 Reserved/ Clock Calendar Day of the Week 
S:55 Last DII Scan Time 
S:56 Maximum Observed DII Scan Time 
S:57 Operating System Catalog Number 
S:58 Operating System Series 
S:59 Operating System FRN 
S:61 Processor Series 
S:62 Processor Revision 
S:63 User Program Type 
S:64 User Program Functional Index 
S:65 User RAM Size 
S:66 Flash EEPROM Size 
S:67 Channel 0 Active Nodes 
S:68 Channel 0 Active Nodes 
S:69 Channel 0 Active Nodes 
S:70 Channel 0 Active Nodes 
S:71 Channel 0 Active Nodes 
S:72 Channel 0 Active Nodes 
S:73 Channel 0 Active Nodes 
S:74 Channel 0 Active Nodes 
S:75 Channel 0 Active Nodes 
S:76 Channel 0 Active Nodes 
S:77 Channel 0 Active Nodes 
S:78 Channel 0 Active Nodes 
S:79 Channel 0 Active Nodes 
S:80 Channel 0 Active Nodes 
S:81 Channel 0 Active Nodes 
S:82 Channel 0 Active Nodes 
S:83 DH+ Active Nodes 
S:84 DH+ Active Nodes 
S:85 DH+ Active Nodes 
S:86 DH+ Active Nodes 
ST9:0 ASCII DATA STORAGE 
ST14:9
T4:0
T4:0/DN RAISE_DELAY GlobalRESTRAIN PIN 
T4:1 RESTRAIN PIN RAISE DELAY 
T4:1/DN POSITIONER TABLE RAISE DELAY 
T4:2 RESTRAIN PIN DROP DELAY 
T4:2/DN DROP_DELAY Global RESTRAIN PIN 
T4:2/TT RESTRAIN PIN DROP DELAY 
T4:3
T4:3/DN
T4:3/TT
U:3 U3 Global
U:4 U4 Global
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Instruction Comment Database
Page 1 Wednesday, April 22, 2015 - 21:41:40
Address Instruction Description
HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Symbol Group Database
Page 1 Wednesday, April 22, 2015 - 21:41:40
Group_Name Description
 
Hexagon Manufacturing Soultions 
Flexible Manufacturing System 
PROD 1601 
 
 
 
 
 
 
 
 
\ 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Programmer: Azhar Niazi and Daniel Breitkreuz 
 
 
1 
 
 
 
 
 
2 
 
 
(PART 1) (MILL) (MATERIAL: ALUMINUM INCH - 2024) 
(HEXAGON MANUFACTURINNG SOLUTIONS INC.) 
(DATE: 4/10/2015 TIME:1:10 PM) 
G20 G28 M39 
N100 G00 G17 G40 G80 G90 
 
M66 (WAIT ROBOT SIGNAL TO START) 
M65 (INPUT _15 OFF) 
G28 (HOME) 
M38 (DOOR OPEN) 
M62 (AUX#1 ON) 
 
M76 (WAIT FOR INPUT 1 LOW, DOOR CLOSES AND START CUTTING OPERATION) 
M39 (DOOR CLOSE) 
 
N110 M03 
N120 S2139 
N130 G00 G90 X1.69 Y.7475 
N140 G43 H1 Z.5 
N150 Z.2 
N160 G01 Z-.005 F3. 
N170 G03 Y.7525 I0. J.0025 F6. 
N180 Y.7475 I0. J-.0025 
N190 Y.8413 I0. J.0469 
N200 Y.56 I0. J-.1407 
N210 Y.94 I0. J.19 
N220 Y.56 I0. J-.19 
N230 Y.6538 I0. J.0469 
N240 Y.3725 I0. J-.1407 
N250 Y1.1275 I0. J.3775 
N260 Y.3725 I0. J-.3775 
N270 G00 Z.5 
N280 Y.685 
N290 Z.19 
N300 G01 Z-.1933 F3. 
N310 G03 Y.815 I0. J.065 F6. 
N320 Y.685 I0. J-.065 
N330 G01 Z-.3767 F3. 
N340 G03 Y.815 I0. J.065 F6. 
3 
 
N350 Y.685 I0. J-.065 
N360 G01 Z-.56 F3. 
N370 G03 Y.815 I0. J.065 F6. 
N380 Y.685 I0. J-.065 
N390 G00 Z.5 
N400 X.75 Y2.4975 
N410 Z.2 
N420 G01 Z-.005 F3. 
N430 G03 Y2.5025 I0. J.0025 F6. 
N440 Y2.4975 I0. J-.0025 
N450 Y2.5913 I0. J.0469 
N460 Y2.31 I0. J-.1407 
N470 Y2.69 I0. J.19 
N480 Y2.31 I0. J-.19 
N490 Y2.4038 I0. J.0469 
N500 Y2.1225 I0. J-.1407 
N510 Y2.8775 I0. J.3775 
N520 Y2.1225 I0. J-.3775 
N530 G00 Z.5 
N540 Y2.4965 
N550 Z.2 
N560 G01 Z-.1867 F3. 
N570 G03 Y2.5035 I0. J.0035 F6. 
N580 Y2.4965 I0. J-.0035 
N590 Y2.5903 I0. J.0469 
N600 Y2.309 I0. J-.1407 
N610 Y2.691 I0. J.191 
N620 Y2.309 I0. J-.191 
N630 G00 Z.0633 
N640 Y2.4965 
N650 Z.0133 
N660 G01 Z-.3733 F3. 
N670 G03 Y2.5035 I0. J.0035 F6. 
N680 Y2.4965 I0. J-.0035 
N690 Y2.5903 I0. J.0469 
N700 Y2.309 I0. J-.1407 
N710 Y2.691 I0. J.191 
N720 Y2.309 I0. J-.191 
N730 G00 Z-.1233 
N740 Y2.4965 
N750 Z-.1733 
N760 G01 Z-.56 F3. 
N770 G03 Y2.5035 I0. J.0035 F6. 
4 
 
N780 Y2.4965 I0. J-.0035 
N790 Y2.5903 I0. J.0469 
N800 Y2.309 I0. J-.1407 
N810 Y2.691 I0. J.191 
N820 Y2.309 I0. J-.191 
N830 G00 Z.5 
N3340 M05 
N3350 M02 
 
N3750 G28 (HOME) 
M38 (DOOR OPEN) 
 
M64 (AUX #1 OFF, SIGNAL ROBOT "CNC DONE") 
 
M63 (INPUT _15 ON) 
 
M106 
N2430 M30 (END OF PROGRAM REWIND AND RESET) 
 
 
 
 
 
 
 
 
 
 
5 
 
 
 
6 
 
 
8.7 Backplot of Pin 2: 
 
 
 
7 
 
(PART 2) (PIN 1) (MATERIAL: ALUMINUM INCH - 2024) 
(HEXAGON MANUFACTURINNG SOLUTIONS INC.) 
(DATE: 4/10/2015 TIME:1:10 PM) 
G28 (HOME) 
G18 G40 G80 G90 
 
N110 M38 (DOOR OPEN) 
N120 M110 (OPEN CHUCK) 
N130 M64 (AUX 1 OFF) 
N140 M65 (CNC "DONE" SINGAL OFF TO PLC) 
 
N150 M66 (WAIT FOR INPUT#1 HIGH) 
N160 M111 (CLOSE CHUCK) 
N170 M62 (AUX 1 IS ON, SIGNALING ROBOT CHUCK IS CLOSED) 
 
N190 M76 (WAIT FOR INPUT#1 LOW, WAITING FOR ROBOT SIGNAL TO CLOSE DOOR) 
N200 M39 (DOOR CLOSE) 
 
 
N220 M06 T0101 (TOOL CHANGE) 
N230 M03 (SPINDLE ON) 
N240 S2400.0 
N250 G00 X.4115 Z.21 
N260 G01 Z.11 F6. 
N270 Z-.611 
N280 X.4546 
N290 G02 X.4838 Z-.623 I0. K-.0413 
N300 G01 X.5 Z-.6393 
N310 X.5707 Z-.5686 
N320 G00 Z.21 
N330 X.3229 
N340 G01 Z.11 
N350 Z-.115 
N360 X.3287 
N370 G02 X.3645 Z-.1356 I0. K-.0412 
N380 G01 X.3795 Z-.1616 
N390 G02 X.385 Z-.1823 I-.0357 K-.0207 
N400 G01 Z-.611 
N410 X.4215 
N420 X.4922 Z-.5403 
N430 G00 Z.21 
8 
 
N440 X.2344 
N450 G01 Z.11 
N460 Z-.115 
N470 X.3287 
N480 G02 X.3329 Z-.1152 I0. K-.0412 
N490 G01 X.4036 Z-.0445 
N500 G00 Z.21 
N510 X.1458 
N520 G01 Z.11 
N530 Z-.115 
N540 X.2444 
N550 X.3151 Z-.0443 
N560 G00 Z.21 
N570 X.0573 
N580 G01 Z.11 
N590 Z-.115 
N600 X.1558 
N610 X.2265 Z-.0443 
N620 G00 Z.21 
N630 X-.0312 
N640 G01 Z.11 
N650 Z-.115 
N660 X.0673 
N670 X.138 Z-.0443 
N680 G00 Z-.025 
N690 X0. 
N700 G01 Z-.125 F3. 
N710 X.3287 
N720 G02 X.3558 Z-.1406 I0. K-.0313 
N730 G01 X.3708 Z-.1666 
N740 G02 X.375 Z-.1823 I-.0271 K-.0156 
N750 G01 Z-.621 
N760 X.4546 
N770 G02 X.4767 Z-.6301 I0. K-.0313 
N780 G01 X.4908 Z-.6443 
N790 X.5616 Z-.5736 
N800 G00 Z-.025 
N810 X-.05 
N820 G01 Z-.125 
N830 X-.0313 
N840 X.3287 
N850 G02 X.3558 Z-.1406 I0. K-.0313 
N860 G01 X.3708 Z-.1666 
9 
 
N870 G02 X.375 Z-.1823 I-.0271 K-.0156 
N880 G01 Z-.621 
N890 X.4546 
N900 G02 X.4767 Z-.6301 I0. K-.0313 
N910 G01 X.4908 Z-.6443 
N920 X.5616 Z-.5736 
N930 G00 Z.21 
N940 M05 (SPINDLE STOP) 
 
N950 M02 (END OF PROGRAM) 
 
 
N960 G28 
N970 M38 (DOOR OPEN) 
N980 M64 (AUX#1 IS ON, TELLING ROBOT PART IS READY TO UNLOAD CNC) 
 
N990 M66 (WAITING FOR ROBOT SIGNAL TELLING ROBOT IS THERE AND THE 
CHUCK CAN BE OPENED) 
N1000 M110 (OPEN CHUCK) 
N1010 M62 (SIGNALING ROBOT CHUCK IS OPENED) 
 
(PIN 2) 
 
N1030 G28 (HOME) 
N1040 G18 G40 G80 G90 
 
N1050 M76 (WAITING FOR ROBOT SIGNAL TELLING THAT ROBOT READY TO LOAD PIN 
2) 
N1060 M38 (DOOR OPEN) 
N1070 M110 (OPEN CHUCK) 
N1080 M64 (TELLING ROBOT THE DOOR AND CHUCK IS OPENED) 
 
M66 (WAIT FOR INPUT#1 HIGH, WAITING FOR ROBOT SIGNAL TO CLOSE 
CHUCK AND START OPERATION) 
N1100 M111 (CLOSE CHUCK) 
N1110 M62 (AUX 1 IS ON) 
 
N1130 M76 (WAITING FOR ROBOT SIGNAL TELLING ROBOT IS IN SAFE POSITION, THE 
DOOR CAN BE CLOSED AND START OPERATION) 
N1140 M39 (DOOR CLOSE) 
 
N1160 M06 T0101 (TOOL CHANGE) 
N1170 M03 (SPINDLE ON) 
10 
 
N1180 S2400.0 
N1190 G00 X.4731 Z.1807 
N2000 G01 X.4024 Z.11 F6. 
N2010 Z-.611 
N2020 X.4546 
N2030 G02 X.4838 Z-.623 I0. K-.0413 
N2040 G01 X.5 Z-.6393 
N2050 X.5707 Z-.5686 
N2060 G00 Z.1807 
N2070 X.3755 
N2080 G01 X.3048 Z.11 
N2090 Z-.611 
N3000 X.4124 
N3010 X.4831 Z-.5403 
N3020 G00 Z.1807 
N3030 X.2779 
N3040 G01 X.2072 Z.11 
N3050 Z-.0962 
N3060 G02 X.2394 Z-.1166 I-.0035 K-.0411 
N3070 G01 X.2543 Z-.1426 
N3080 G02 X.2599 Z-.1633 I-.0358 K-.0207 
N3090 G01 Z-.611 
N4000 X.3148 
N4010 X.3855 Z-.5403 
N4020 G00 Z.1807 
N4030 X.1803 
N4040 G01 X.1095 Z.11 
N4050 Z-.096 
N4060 X.2036 
N4070 G02 X.2172 Z-.0983 I0. K-.0413 
N4080 G01 X.2879 Z-.0276 
N4090 G00 Z.1807 
N5000 X.0826 
N5010 G01 X.0119 Z.11 
N5020 Z-.096 
N5030 X.1195 
N5040 X.1903 Z-.0253 
N5050 G00 Z.1707 
N5060 X-.015 
N5070 G01 X-.0857 Z.1 
N5080 Z-.096 
N5090 X-.032 
N6000 X.0219 
11 
 
N6010 X.0926 Z-.0253 
N6020 G00 Z-.0353 
N6030 X-.1251 
N6040 G01 X-.0544 Z-.106 F3. 
N6050 X-.032 
N6060 X.2036 
N6070 G02 X.2306 Z-.1216 I0. K-.0313 
N6080 G01 X.2457 Z-.1476 
N6090 G02 X.2498