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The ToolScope has an internal message bus. With this bus, the monitoring sends event-oriented information to the monitored hardware. For each event to be reported, a message is placed on the bus. Events can only be transferred consecutively. Each event is assigned an event number and a messaging channel, amongst other things.

The number pair (event / channel) is output to the PLC of a machine tool by the BRINKHAUS example block FB391. The consistency of a number pair (event / channel) is always guaranteed if an event code not equal to 0 is specified.

The time period for which the event remains at the output is not defined. It is only guaranteed that an event is present for at least one PLC cycle. As soon as the example block has placed the event at its outputs once, it acknowledges the event to the ToolScope. This can result in a new event already being displayed in the next PLC cycle.

By linking the information running through the message bus, the integration of the monitoring in the machine tool can be significantly improved. KOMET offers an advantage here, which enables you to fulfill special customer requests using the standard version.

Suggestions:

  • Trigger a feed lock immediately if the machine is not at least in access level "Schlüsselschalterstellung 3" AND a process starts, which the monitoring would first have to learn (and which thus was apparently not learned).
  • When starting a monitored process, switch a traffic light from amber to green. Following the successful end of the process, switch the traffic light back to amber, or red.

In combination with the fact that our PLC block issues two bits as status displays, which show whether the monitoring can currently monitor, it is possible to implement almost any safety functions in the machine tool.

Part of the code is only transferred if a certain setting is active in the Profibus driver. Activation of these settings means that a lot of messages are output via the message bus and a "queue" of messages forms. If there is a queue, the most important message is always output first. The others are transferred with a delay. If possible ONLY error messages should be transferred on the message bus. Therefore, "Send detailed process information" is OFF by default.

Number codes

Number code

Event

Dependent on

1

Tolerance-range limits exceeded/breakage alarm

 

2

Red limit/maximum value exceeded

 

3

Yellow limit/wear limit exceeded

 

4

Green limit/missing limit triggered

 

5

Undocumented

 

6

Undocumented

 

7

Undocumented

 

8

Undocumented

 

9

A channel begins monitoring a process

With small image: "Send detailed process information"

10

A channel has ended monitoring of a process

With small image:
"Send detailed process information"

11

Advance warning limits for tolerance ranges / breakage alarm (number code "1") were reached

 

12

A manual input has been made in the "Set process ID" mask and at least one of the mask fields is not empty.

 

13

Alarm through quantity monitoring

 

14

User has pressed a softkey to confirm that an alarm was correct

 

15

User has pressed a softkey to specify that an alarm was a false alarm

 

16

Advance warning limit for Yellow Limit / Wear (number code 3) was breached

 

17

A channel has just ended monitoring and the process being monitored had to be learned

With small image: "Send detailed process information"

18

A channel is just beginning monitoring and the process being monitored is being learned

With small image: "Send detailed process information"

19

The monitoring has just been (re?) activated. This event is kept until the message "Hochlauf abgeschlossen" is displayed.

 

20

The monitoring has just been deactivated.

 

21-30

A monitoring channel transfers additional information about an alarm message

Meaning with "Window" monitoring:

In addition to event "1" the following is transferred

  21 >> Alarm at upper limit
  22 >> Alarm at lower limit
  23 >> Alarm at left limit
  24 >> Alarm at right limit

The "Window" monitoring sends the above-mentioned events directly to the PLC when they occur. Any alarm delays are ignored.

"In the event of alarms, send additional information"

31

Process data / measurement data was transferred to an external instance

Example: Feed lock, until measurement data has been copied into the QA documentation system

Appears only with customer-specific programming

Assignment of monitoring alarms to error codes of the internal message bus and outputs of the PLC block

You find the alarm codes which each monitoring method of a ToolScope generates, below.

Our PLC example block (e.g. FB391 for Siemens) evaluates the internal message bus and decodes the most frequently used alarm outputs at the block outputs, where they are provided as a bit.

The alarm outputs remain set until the "Delete alarm" block input is set.

Alarm generating window and event

Code

Tolerance range based monitoring

Tolerance range is breached
Wear alarm (yellow)
Missing alarm (green)

1 (PLC: "Breakage")
3 (PLC: "Wear")
4 (PLC: "Missing")

Dynamic monitoring

Dynamic or static limit is breached

 

1 (PLC: "Breakage")

Average, average without offset

Wear alarm (upper limit)
Missing alarm (lower limit)

 

3 (PLC: "Wear")
4 (PLC: "Missing")

Maximum value

Value is above limit
Advance warning limit

 

2 (PLC: "Maximum")
3 (PLC: "Wear")

Minimum/maximum

Upper limit has been breached
Bottom advance warning limit has been breached

Lower limit has been breached
Bottom advance warning limit has been breached

 

1 (PLC: "Breakage")
2 (PLC: "Maximum")

3 (PLC: "Wear")
4 (PLC: "Missing")

MTV548

Red limit
Yellow limit
Pre-warning limit
Missing limit

 

2 (PLC: "Maximum")
3 (PLC: "Wear")
16
4 (PLC: "Missing")

GEP11TF12

Red limit
Yellow limit

 

2 (PLC: Maximum)
3 (PLC: Wear)

Batch counter

Permitted quantity was exceeded

 

13 (PLC: "Use Counter")

Window

A rule regarding the characteristics of a window edge (signal must pass this edge, signal must not pass the edge, etc.) has been breached.

 

1 (PLC: "Breakage")