Driver for the Logimat HLL

Driver for Logimat HLL

Introduction

The Logimat HLL Control module is a collection of several individual drivers, used for different versions of the Logimat controlled by the Omrom PLC. During the years, there have been a number of different versions with different PLC firmware. 

Shark Control Type Logimat Version Notes
LogimatOmron Year: 1999-2004. First Handler A/S version with the Omron PLC (1999-2004).
Interface: Serial or Ethernet by Moxabox.

LogimatOmronSimple

Year: 1999-2004. Special version of with the first Logimat version with a simplicifed interface with a minimum interaction with the PLC. Used for PLC firmware/versions with "strange behavioir". 
LogimatOmron2 Year: 2004-2013.


Interface: Serial or Ethernet by Moxabox.

LogimatOmron3 Year: 2012-2013. Special version with support for IHO 
Interface: Serial or Ethernet by Moxabox.
LogimatOmron4 Year: 2013-2014. Special version supporting multiple openings. 
Interface: Serial or Ethernet by Moxabox.
LogimatOmron5 From year 2012Q2 and later with firmware 55.2

The LogimatOmron5 Shark Control Module is designed for the controlling the Logimat from year 2012Q2 and later with firmware 55.2 or newer with the Omron PLC. This is the version after SSI took over the Logimat. It supports advanced features like:

  • IHO with variable position spacing.
  • Functions for optimization support.
  • The tray tilt function.
  • Multiple openings.
LogimatOmron6 Update Logimats. Used for older Logimats, with replaced Omron PLC because the original PLC now is obsolete.
Interface: Ethernet UDP.

 

What features actually are available, depends on the licence key used to activate Shark.

Configuration

The configuration of the module is done in the Shark Registry under:

*devices.verticallifts.<module name> Import parameters *

Registry Parameter

Values

Description

Type

LogimatOmron5
AutomatSimulateIHO

This defines the Logimat type. AutomatSimulateIHO can be used for simulation.

IHO_Supported

true|false

Set to true if the Logimat is equipped with IHO functionality.

Connection

MoxaGateway:ip:port / COM1 / COM2

Example: use a Moxabox: MoxaGateway:10.1.1.1:4001

IHO_Locked

true|false

IHO is supported, but all tray positions are locked. 

PositionSpacing

25

Distance between each position. Default is 25mm.

AutoAcceptTrayHeightChanges

true|false

If set to true, changes in goods height will be accepted automatically. Default is false.

DefaultTrayHeight

100

Height of the empty tray. Default is 100 mm

TrayClearance

25

The is the minimum security distance between trays. It includes bending and measurement tolerances.

TrayConfigBackupFile

Filename

Shark makes a backup file containing the current PLC tray configuration. This is the name of the file. Default is trayconfig-backup.txt

SuppressErrorEvents

true|false

If true most error events will be suppressed. This will prevent error menus to be displayed in Shark. Indented to be used in setups where Shark is controlled by an external Host via the Web Service. Default is false.

AdjustLiftToTrayHeightLimit

0.3

This is a function that can be used if the variable lift is available. If the tray height is heigher that this parameter, the lift will be lowered to compensate for the height. It will slow down the operation speed because the Logimat will stop while the lift is adjusted.

StartUpDelayMS

0

This value will force a wait before accessing the PLC. The delay is in ms.

CacheLifeTimeMS

100

To optimize PLC communication speed, data is read in blocks and cached in PC memory. This is the maximum allowed age of data in ms before they are refreshed.

CheckPLCAutomaticMode

true|false

Check if the PLC is in remote-control mode.

Debug

true|false

Enables extended logging to the database.

DefaultStatusPollDelayMS

15000

Time in ms between status is read when the Logimat is idle.

DemoModeDelay

10

Time the tray will stay at the opening when in demo mode.

DemoModeEnabled

true|false

Mode for automatic run-mode.

IgnoreErrors

true|false

Special mode to ignore errors from the PLC. Used to force the Logimat to operate, in case of a none important sustained error.

LogTrayMoveToDB

true|false

Logs to the database when the tray is requested, arrives at opening, returned and at returned position. Also calculate and updates ETA for the tray, used to optimize the picking sequence.

MaxIdlePolls

5

If NoIdlePoll=True this is the maximum number of polls.

NoIdlePoll

true|false

If true polling of Logimat status will stop when the machine is idle. Minimizes bus load (shared PLC bus) or avoid unnecessary network trafic.

PackMode

Manually

Packing strategi for IHO. Only Manually is supported.

ResetOrderStack

true|false

If true the PLC order stack will be reset for every tray request.

Connection the PC to the Logimat

Moxa Box

For interfacing to serial devices (RS232/RS422/RS485), it is preferred to use an Ethernet gateway to enable the device to be connected directly to the network. Compared to a direct connection, it has a number of advantages:

Logisoft uses typical a Moxa NPort gateway. The NPort module is running in “TCP Server Mode”. Other gateways can be used as well, for example Lantronix, but is not directly supported by Shark.

There is no software driver installed on the PC. Logisoft communicates directly to the Moxa box by Ethernet.

The automats must be connected together in a PLC network.

The Logimat PLC must be configured for the correct communication speed, “switch 4” on the PLC must be set to “on”, else the communication will not work. (see picture below).

The PLC switch that must be set to make the communication work

Connecting a NPort Moxa bus to the PLC Bus

There a different PLC versions. This picture shows one possible configuration, where the PLC is located below the opening on the floor

The connections from the PLC bus to the Moxa box are:

Logimat Wire Moxa NPort
White RS422 - T+
Green RS422 - T-
Brown RS422 - R+
Yellow RS422 - R-
SG GND

The Moxa box gets power from the PLC 24V supply.

Configuration of the Moxa Box

Before installation decide if the module should use a fixed IP address or a dynamic. In case a fixed IP address is preferred, one must be given by a network administrator.

The module has a fixed IP address when delivered that is 192.168.127.254. To setup the module configure a computer to work in the 192.168.127.XXX segment (for example by setting the computer to a fixed IP address in that range).

When the module is connected to the network and the computer used for configuration is ready open from the computer the web configuration tool in the module (http://192.168.127.254).

In basic settings, set a name for the module, for example MOXA1, this name must be unique if more than one module exists in the same network. Press “Submit” (this will restart the module).

Open the web configurator again at http://192.168.127.254. Now select “Network Settings” .

For dynamic IP address:

For a fixed IP address:

General setup for Port 2

Operating Settings  
Operation Mode TCP Server Mode
TCP Alive check time 3 minuts
Max Connections 4
Local TCP port 4002
Force transmit 50ms
Serial Settings  
Baudrate 9600
Data bits 7
Stop bits 2
Parity Even
Flow control None
FIFO Enabled

Configuration of the Omron PC (obsolete)

Some Logimats has a built-in PC where Shark is installed. To install software on the PC, follow the procedure:

  1. From a command prompt run: ewfmgr c: -disable
  2. Restart the PC
  3. Install the software
  4. From a command prompt run: ewfmgr c: -enable
  5. Restart the PC

IHO

Intelligent Height Optimization. This is a mode where Shark maintain trays with variable heights.

Tray Heights

This chapter describes the logical model used for the automat. Some general rules:

*Model of the Logimat, with positions collected in sections and sections separated by beams or other obstacles. *

*Definition of óne tray group. *

Location Light

The module supports the built-in pointer in the Logimat (LogiPoint).

The LogiPoint pointer for the Logimat does not require any software calibration, besides that the basic parameters must be set correctly. Although it should not be needed, it is still possible to set some basic calibration parameters.

Before the pointer can be used it must be mechanical calibrated. After initialization of the light, either by restarting Shark Control or from the Logimat it self, the red spot should point at the lower, right corner of the tray.  If that is not the case, the Logimat needs maintenance.

It is also important that the light points perpendicular to the tray (90 degrees).

 

Registry Setup for the LogiPoint.

The calibration parameters for the light pointer is set from the Shark Registry:

 

devices.verticallifts.<module name>.LocationLight ..

Registry Entry

Data type

Value

Description

AutoResetMinuts

Integer

5

The location light will go to the reset position and thereby auto calibrate, when the pointer has been idle for the specified number of minuts.

CalibratedLiftHeight

Float

1.0

Height of lift in meter in the calibrated position.

CalibratedLightDistance

Float

1.0

Distance of light in meter from mirror to the bottom of the tray.

CalibratedLightDistanceTilt

Float

1.2

Distance of light in meter from mirror to the bottom of the tray when the tray is tilted.

LiftAngleZero

Float

50

Angle of the light in degrees between light and the bottom of the tray (see figure).

LiftAngleZeroTiltTop

Float

60.0

Angle when the lift is a top position (degrees)

LiftAngleZeroTiltBottom

Float

60.0

Not used

MaxRegXValue

Integer

4000

Maximum number written to the x position register. This can be used to limit the range of the pointer.

MaxRegYValue

Integer

400

Maximum number written to the y position register. This can be used to limit the range of the pointer.

StepsPrM_X

Integer

 1020

Defines how many steps the PLC needs to step 1 meter in the X direction.

Default is 1020.

StepsPrM_Y

Integer

 4100

Defines how many steps the PLC needs to step 1 meter in the Y direction.

Default is 4100.

TrayDepth

Float

0.82

Depth of tray in meter. For example if the tray dimension is 3000mmx820mm, this value is 0.82.

TrayWidth

Float

3.0

Width of tray in meter.

TrayHeightCalibrationFactor

Float

0.0

Value between 0 and 1. Deactivated with 0, if 1.0 the pointer will be adjusted to point to the top of the box location.

XOffset_M

Float

0.0

Use this value to adjust where the pointer points, when it is a zero position. Normally the light should point to the lower right corner when at zero position, but this can be modified using this parameter. Distance from tray right wall to the spot, measured in meter.

YOffset_M

Float

0.0

Use this value to adjust where the pointer points, when it is a zero position. Normally the light should point to the lower right corner when at zero position, but this can be modified using this parameter. Distance from tray front wall to the spot, measured in meter.

Parameters used when tilt is not enabled:

Parameters used when tilt is enabled:

 

 

Top View

Seen from side

Calibration Procedure

Follow this procedure to calibrate the light pointer.

Step 1
First the pointer must be calibrated mechanical, so zero points at the lower, right corner in the tray.

Shark Control command to reset the pointer: LIGHT:BLANK

If it is not possible to make the mechanical adjustment, use the XOffset_M and YOffset_M parameters to specifiy an offset.

Shark Control commands for online (telnet) changes of the parameters (changes will be lost after restart) :

LIGHT:ConfigStepX StepsPrM_X
LIGHT:ConfigStepY StepsPrM_Y
LIGHT:ConfigZero X,Y

Step 2
If Tilt is supported: Move the lift to the bottom position.
If Lift is supported place the tray at the lowest possible position.

Step 3

If the pointer does not point to the lower right corner of the tray when the pointer is at zero position. Measure the offset from the tray corner to the pointer in mm.

Step 4
Move the pointer to the upper left corner.
 

Shark Control command: LIGHT:GO 0,1

Measure the distance in mm. and enter the X,Y values as MaxRegXValue and MaxRegYValue.

Step 5
Measure the distance from the pointer to bottom of the tray, enter this value as CalibratedLightDistance (meter).

Step 6
Measure the dimensions of the tray and enter as TrayWidth (meter) and TrayDepth (meter).

Step 7
If Lift is supported: measure the height of the bottom of the tray from the ground and enter as CalibratedLiftHeight (meter).
If Lift is not supported: Set CalibratedLiftHeight to 0.

Step 8
If Tilt is supported: Tilt the tray and measure the height of the tilt at the back and enter the value in TiltHeightMax (meter).
If Tilt is not supported: Set TiltHeightMax to 0.

Lift

The two lift systems, used by the Logimat, are both supported:

  1. The first solution are 2 or more fixed bearings. Shark will choose the nearest bearing, according to the user requested height.

  2. The second solution is where the height is controlled by a variable motor controlled system.

Configuration:

Registry Parameters

Value

Description

LiftType

0|1|2

0: No Lift supported.
1: Lift with fixed height.
2: Variable lift height

AdjustLiftToTrayHeightLimit

Height of tray in meter.

If the tray height is heigher that this parameter, the lift will be lowered to compensate for the height. It will slow down the operation speed because the Logimat will stop while the lift is adjusted.

To enable the Shark Client set the “Feature” bit 7 to 1 (value 64 if empty).
To set the lift height for each user.

Tilt

Enable Tilt in Shark pre-2012Q1

To enable the Shark Client set the “Feature” bit 4 to 1 (value 8 if empty). The features are set in System Configuration → System Parameters → Features.

 

 

To be used in the the “Floating Batch Pick” window, it must also be enabled for this panel in the registry parameter.

Enable Tilt in Version 2012Q1 and later

Tilt must first be enabled in:

  1. In the registry Shark Applications → Forms → FloatingBatchPick, set “LiftAndTiltSupported” true.
  2. For each Logimat in the registry Devices → VerticalLifts → <name>, set “Tilt” true.

 

Setting Trays to Tilt

When Tilt is enabled and the client is restarted, a new column is available for the tray configuration. Here Tilt can be enabled/disable for each tray individually.

 

 

LogiStub

The LogiStub is supported. To enable the buttons in the Logimat screen, the function must be enabled in the Registry.

 

 

It must be enabled for each Logimat (workstation) supporting this functionality:

 

 

Set Shark Application à Forms à Logimat à <workstation> à ShowStub=true

 

Multiple Openings

Support for Multiple openings or gates is used when the Logimat is equipped with more picking openings.

There is no special configuration of the Shark Control module, but the client must send the right gate number.

 

Master PC Configuration

Check list to configure the master PC (Logisoft registry entries) :

  1. SharkControl.Port=8089
    Other port numbers can be used, but 8089 is default. This is the port number that an external PC can access Shark Control.
     
  2. Shark.Application.Config.<MasterPCName>.AutomatGate=1
    Tell which opening the Master PC will control.
     
  3. Shark.Application.Config.<MasterPCName>.AutomatGateFrontView=true
    Orientation of the opening, true for normal front opening, false if in the back side of the machine.
     
  4. Shark.Application.Config.<MasterPCName>.ControlModules=ModuleID
    This is the moduleID from the Module database table for the module (Logimat) that has to be controlled by this PC.
     
  5. Shark.Application.Config.<MasterPCName>.LocationPattern=pattern_to_display
     
  6. Shark.Application.Config.<MasterPCName>.LogimatModuleName=name_of_logimat
     
  7. Shark.Application.Config.<MasterPCName>.SharkControl=Embedded
    Tell Shark that this PC should host Shark Control.
     
  8. Shark.Application.Config.<MasterPCName>.SharkControlPort=8089
    The port that is used for Shark Control Communication.

Slave PC Configuration

Check list to configure the slave PC(s) (Logisoft registry entries) :

  1. SharkControl.Port=8089
    Other port numbers can be used, but 8089 is default. This is the port number that an external PC can access Shark Control.
     
  2. Shark.Application.Config.<SlavePCName>.AutomatGate=2
    Tell which opening the Master PC will control.
     
  3. Shark.Application.Config.<SlavePCName>.AutomatGateFrontView=true
    Orientation of the opening, true for normal front opening, false if in the back side of the machine.
     
  4. Shark.Application.Config.<SlavePCName>.ControlModules=ModuleID
    This is the moduleID from the Module database table for the module (Logimat) that has to be controlled by this PC.
     
  5. Shark.Application.Config.<SlavePCName>.LocationPattern=name_of_logimat
     
  6. Shark.Application.Config.<SlavePCName>.LogimatModuleName=name_of_logimat
     
  7. Shark.Application.Config.<SlavePCName>.SharkControl=MasterPCName
    Tell Shark that this PC must communicate to the MasterPC, to control the Logimat.
     
  8. Shark.Application.Config.<SlavePCName>.SharkControlPort=8089
    The port that is used for Shark Control Communication.

 

Test Commands

To test the multple opening function, the following commands are usefull (used from the Telnet interface):

DEFAULTGATE <gate number>

DEFAULTGATE?

 

For example to retrieve trays to opening 2, use the commands:

>DEFAULTGATE 2

>GETTRAY 5

>GETTRAY 7

 

External Control of the Logimat

There is an optional possibility to perform low level control of the Logimat by using the Web Service interface to Shark Control. The Web Service is a RESTful implementation.

Where Sharks works at a high level with article numbers, location address, etc. the low level interface support control at tray level with basic features like:

The Web Service interface must be enabled to make it available. It is done in the Shark Registry under Registry->Shark Control->Web Server.

The default port number is 8095, but this can be changed in the configuration.

Communication between an external system and Shark/Logimat for low level control.

 

Configuration of the Web Service Port in Shark.

Most of the commands, requires a module name to identify the Logimat. This is due to the fact, that one PC may control more than one Logimats.

The Web Interface can be easily testet by using a standard Web Browser. If it is not possible to access Shark from an external PC, please check the Windows Firewall that might block for external access.

The interface is case sensite, all commands must be lower case.

 

The response can be seen in the browser window.

The response is XML formattet and relative simple to interprete.
 

Supported Commands

 

The following commands are supported.

/command/logimat/<module>/gettray

Move a tray to the gate. If there already is a tray at the gate, this will be returned first.

The call will return immediately, to get status and information about when the tray will be ready, use the «statusxml» command to poll for current status.
 

Command

http://<host>:<port>/command/logimat/<Module>/gettray

Parameters

traynumber=<tray>

tilt = true|false  (optional, default false)

gate=1|2|3|4 (Opening number)

Response

<SharkControl> 

  <Status>OK|Error</Status> 

  <ErrorCode>error code</ErrorCode> 

  <Message>error message</Message>

</SharkControl> 

Example

To get tray 3:
http://localhost:8095/command/logimat/a1/gettray?traynumber=3

To get tray 3 with tilt:

http://localhost:8095/command/logimat/a1/gettray?traynumber=3&Tilt=1

 

To get tray 3 from opening 2:

http://localhost:8095/command/logimat/a1/gettray?traynumber=3&Gate=2

 

Procedure to get a tray with support for changed height:

 

 

/command/logimat/<module>/returntray

Return the current tray at gate.
 

If the height is changed, the tray will not be returned, but will generate an error. To automatically accept a changed height, add the “accept=true” parameter to the command.

Command

http://<host>:<port>/command/logimat/<module>/returntray

Parameters

gate=1|2|3|4 (Opening number)

Response

<SharkControl> 

  <Status>OK|Error</Status> 

  <ErrorCode>error code</ErrorCode> 

  <Message>error message</Message>

</SharkControl>

Example

Return the current tray in the opening:
http://localhost:8095/command/logimat/a1/returntray

 

Return the current tray from opening 2:
http://localhost:8095/command/logimat/a1/returntray?Gate=2

 

 

 

 

/command/logimat/<module>/returntrayacceptheight

Return the current tray at gate. If the height is changed it will be accepted immediately.

 

Command

http://<host>:<port>/command/logimat/<module>/returntrayacceptheight

Response

<SharkControl> 

  <Status>OK|Error</Status> 

  <ErrorCode>error code</ErrorCode> 

  <Message>error message</Message>

</SharkControl>

Example

Return the current tray at gate:
http://localhost:8095/command/logimat/a1/returntray

Returns the current tray and accept any height changes automatically:
http://localhost:8095/command/logimat/a1/returntrayacceptheight
 

 

 

 

/query/logimat/<module>/statusxml

Returns the current automat status formatted as XML.

It Can be used to detect if the Logimat is busy working, ready for the next operation or in an error state.
 

 

 

Command

http://<host>:<port>/query/logimat/<module>/statusxml

Parameters

 

Response

<SharkControl> 

  <Status>OK|Error</Status> 

  <ErrorCode>error code</ErrorCode> 

  <Message>Error message</Message>

  <Response>

       <State>state</State>

       <Text>status text</Text> 

  </Response>

</SharkControl>

 

 

Get status for automat A1:

http://localhost:8095/query/logimat/a1/statusxml

 

Status: Is OK when the command is accepted.

State: Is the current state of the Logimat, it can be READY, BUSY, ERROR, NOT_READY or MANUAL. MANUAL means the Logimat is put into manual control by the operator and cannot be remotely controlled, NOT_READY means that the Logimat is not connected or it has not been possible to read the configuration from the Logimat.

Text: Is a textual description of the current state and optional an error message.

 

 

/command/logimat/<module>/light/go

Set the location light to a specific position in the tray as a floating number between 0 and 1.

Some positions:

     
Tray Position XPos Ypos
Lower left corner 0.0 0.0
Upper left corner 0.0 1.0
Upper right corner 1.0 0.1
Center 0.5 0.5

 

Command

Opening 1:

http://<host>:<port>/command/logimat/<module>/light/go

 

Opening 2:
http://<host>:<port>/command/logimat/<module>/light2/go

Parameters

xpos=<0.0 .. 1.0>
ypos=<0.0 .. 1.0>

tilt=true|false

Response

<SharkControl> 

  <Status>OK|Error</Status> 

  <ErrorCode>error code</ErrorCode> 

  <Message>error message</Message>

</SharkControl>

Examples

Set the light to the middle of the tray (0.5,0.5) :

http://localhost:8095/command/logimat/a1/light/go?xpos=0.5&ypos=0.5

 

Set the light to the middle of the tray (0.5,0.5) with tilt activated:

http://localhost:8095/command/logimat/a1/light/go?xpos=0.5&ypos=0.5&tilt=true

 

 

 

/command/logimat/<module>/lift?Height=<height>

Set the height of the optional lift.

The lift cannot work with a tray in the opening or when the Logimat is operating.

Command

http://<host>:<port>/command/logimat/<module>/light/go

Parameters

height=<0.8 .. 1.0> The height of the lift in meters

Response

<SharkControl> 

  <Status>OK|Error</Status> 

  <ErrorCode>error code</ErrorCode> 

  <Message>error message</Message>

</SharkControl>

Example

Set the lift height to 0.9 meter:

http://localhost:8095/command/logimat/a1/lift?height=0.9

 

/command/logimat/<module>/reseterror

This will reset a PLC error.

Command

http://<host>:<port>/command/logimat/<module>/reseterror

Parameters

none

Response

<SharkControl> 

  <Status>OK|Error</Status> 

  <ErrorCode>error code</ErrorCode> 

  <Message>error message</Message>

</SharkControl>

Example

Reset an error condition:

http://localhost:8095/command/logimat/a1/reseterror

 

 

Error Codes

The following error codes may be returned.

Error Code Description
1 OK
1000 Syntax error
1018 General error code. Will for example be returned due to an unknown REST command. This can happen during initialization, before the Logimat module is started.
1028 Not yet initialized.
1203 Automat is in manual mode.
1204 Goods height is exceeded.
1235 Goods height has changed. This means that the tray will not be returned until the change of height has been accepted.

 

 

Command Interface

The Telnet Interface to Shark Control supports low level control of the Logimat for debugging. Some convenient commands are (the examples is if the module is called A1):

Get a list of all trays

>LOGIMAT:A1:TRAY:LIST?

**Get information about a specific position: **

>LOGIMAT:A1:TRAY:POSITION? <position number>

Returns: <position>,<tray>,<height in mm>

Set a specific position:

>LOGIMAT:A1:TRAY:POSITION <position>,<tray>,<height in mm>

 

 

Simulation Mode

A simulation mode is available where the physical Logimat is simulated. The purpose is not make a 100% simulation, but to test an installation before the physical automats are available. It can also be used with Shark installations used for testing.

To use the simulation mode, set the Shark Control device type to “AutomatSimulateIHO”.

 

The simulator needs some knowledge about the possible configuration of the automat. Normally this information will be retrieved from the PLC in the machine, but when the machine is not available the information is needed somehow else. Shark Control allows the configution to be read from a file. Which file is specified in the Shark Registry.

 

The parameter is named “LoadTrayConfigFile”. The file is a text file that can be generated from a real installation, using the Shark Control command: 

Logimat:A1:Tray:SaveTrayConfig <filename>

(replace “A1” by the module name)