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Debuging_Factory.md

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Debuging_Factory.md

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Debugging Manual for Factory and PLC

Abbreviations

Abbreviation Meaning
SENS Light barrier (have an LED and an Light sensor)
REF_SWITCH Reference switch, to find a start position for an axis
CB Conveyer belt
GR 3D-Robot with claw attachment
VG 3D-Robot with vacuum gripper attachment
MPS Multi Purpose Station
PM Punching Machine
SL Sorting Line
INDX Index line with drill and mill
WH Warehouse

Debugging Tools

Status-LEDs on the PLC

3 LEDs can be found on each controller (the one with the LAN-Port) and 2 on each expansion Modul

LEDs on Controller

LED Color Meaning
Power green RevPi Core running
red The piControl driver resets, the modules connected to the PiBridge are reinitialized.
off No Power
A1 green blinking Control Software is running
red blinking Error/Problem in Factory
static/off Control Softwarenot running
A2 green blinking A Production-Line is running
red blinking Error/Problem in a Production-Line
static/off No Production-Line is running

LEDs on expansion modules

LED Signal Meaning
Power on, green RevPi Core is connected to the power supply.
flashes, red Connection to RevPi Core is not yet set up (initialization phase).
on, red Connection to RevPi Core is interrupted. Check if PiBridge is plugged properly.
OUT off Connection to RevPi Core is not yet set up (initialization phase).
on, green Outputs are ready for use.
flashes, red Outputs are defective. Check the connection to the power supply.
on, red No or low power supply. Check if your device is supplied by the permitted voltage range (10.7 V – 28.8 V).
IN on, green Inputs are ready for use.
off Connection to RevPi Core is not yet set up (initialization phase).
on, red No power supply to the inputs on the plug X2. Check the connection to the power supply.

RevPiCommander

Download at: https://revpimodio.org/en/sources/revpipycommander/

Abilities:

  • Start/Stop/Restart Control-Software
  • Display general Log
  • Configure PLC
  • Read Inputs
  • Set Outputs

PLC watch mode (read inputs, set outputs)

When a fault is detected by the Control-Software it is helpful to check the displayed sensor/ corresponding actuator.

It shows live which Sensor is detecting something and which motor is running.

Stop the Control-Software bevor using it

PiTest

Simple Commandlinetool on the PLC. Same functionality as PLC watch mode on the RevPiCommander

Tutorial: https://revolutionpi.com/en/tutorials/software/pitest-verwenden

Logging Systems

MQTT-Log

All important events are sent via MQTT

General-Log

Logs the important events.

  • Not persistent over reboot
  • Can only be read with RevPiCommander by selecting log on the interface

Detailed-Log

Logs all events on the PLC

  • Includes the general-log
  • found on the plc at /var/lib/revpiload/plc_code/log

Debugging Errors and Problems

If the factory stops or halts you can look at the errors in the mqtt_signals or the log.

How to find the problem sensor or actuator

  • The first part of a sensor/actuator name is the machine it is on (CB1_SENS_END , the machine is CB1)
  • Most of the time the error messages includes a sensor even if the sensor isn't the part that has a fault
    • see the examples below for details

Error examples and the corresponding reasons

  • 'PROBLEM': 'SensorTimeoutError: CB1_SENS_END no detection in time'
    • Product didn't reach the Light Barrier bevor a give timeout is reached
    • Reasons can be:
      • Product ist stuck somewhere or was dropped
      • Problem with the CB-Motor
      • Problem with the Sensor
  • 'PROBLEM': 'GetProductError: GR2 :Product still at Sensor, grip failed'
    • Sensor at gripping position still detect something even after gripping and moving away
    • Reasons can be:
      • Robot position is of, so it tries to grip at the wrong location
      • Problem with Claw-Motor
  • 'PROBLEM': 'SensorTimeoutError: GR2_ROTATION_ENCODER :Value 1400 not reached in time'
    • The encoder for the rotation axis didn't reach the value in time
    • Reasons can be:
      • Problem with Motor
      • Robot stuck / collided with something
      • Problem with encoder (sensor)
  • 'PROBLEM': 'SensorTimeoutError: GR2_REF_SW_ROTATION_ENCODER no detection in time'
    • While running to to reference switch a timeout occurred
    • Reasons can be:
      • Problem with Motor
      • Robot stuck / collided with something
      • Problem with reference switch (sensor)
  • 'PROBLEM': 'LookupError: WH: No empty spaces left.' or 'LookupError: WH: Color RED not found.'
    • Color or no space found when looking in the wh_content.json file.
    • Free up space or update the file with mqtt

Reasons for Problems at Motor/Sensor

Motor
  • Cable lose at the machines pcb
  • Cable lose at plc terminal
  • Axis/CB etc. is stuck
  • A gear is lose
  • Motor broken
Sensor
  • Cable lose at the machines pcb
  • Cable lose at plc terminal
  • At Light barriers:
    • LED not working
    • LED misaligned
  • Sensor broken

HOW TO fix a Problem

  • Find the Sensor/Actuator with the problem
  • Look at Error examples and find the reason
    • Use RevPICommander or PiTest to test actuators and sensors without the program running