By
Alfred Masadhi Selo
A Thesis submitted to the FACULTY of ENGINEERING DEPARTMENT of MECHATRONICS
In Partial Fulfillment of the Requirements for BACHELOR’S DEGREE
IN
MECHATRONICS
SWISS GERMAN UNIVERSITY Campus German Centre Bumi Serpong Damai – 15321
Island of Java, Indonesia www.sgu.ac.id
July 2008
Revised after Thesis Defense on August 6th 2008
STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, not material which to a substantial extent has been accepted for the award of may other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
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Alfred Masadhi Selo Date
Approved by:
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Advisor, Tutuko Prajogo, PhD Date
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Co-Advisor, Dr. Ir. Prianggada Indra Tanaya, MME Date
______________________________________ ________________
Chairman of the Examination Steering Committee Date
Alfred Masadhi Selo
Designing of Human Machine Interface (HMI) and Integration into FESTO Modular Production System (MPS)
By
Alfred Masadhi Selo
SWISS GERMAN UNIVERSITY Bumi Serpong Damai
Tutuko Prajogo, PhD, Major Lecturer and Advisor Prianggada Indra Tanaya, Ir. Dr. MME, Co-advisor
The main purpose of this thesis is to design a computerized Human Machine Interface for the Festo MPS stations. The graphical user interface will portray the statuses of each station in detail. Users will also be able to control the stations remotely. Two approaches will be discussed in this thesis. A microcontroller coupled with opto-isolators board will act as an external controller from PC to the PLC. The other approach is by using a proprietary application, WinCC, to access the Siemens PLC directly through the serial port.
DEDICATION
I dedicate this thesis to those who wish to study HMI. May this thesis would give them insights in designing an HMI system.
Alfred Masadhi Selo
ACKNOWLEDGEMENTS
The author wishes to express the utmost gratitude to Tutuko Prajogo, PhD; Dr. Ir.
Prianggada Indra Tanaya, MME; Dipl. –Ing Maralo Sinaga; and Cepi Hanafi SST for their guidance and help in the course of the thesis project.
And lastly, the author would also like to thank the SGU staffs for providing access to the mechatronics labs until late hours.
TABLE OF CONTENTS
Title Page...1
Statement by the author...2
Abstract...3
Dedication...4
Acknowledgements...5
Table of Contents...6
List of Tables...8
List of Figures...9
CHAPTER 1 INTRODUCTION...11
1. 1. Overview...11
1. 2. Background and Thesis Purpose...12
1. 3. Thesis Scope...12
1. 4. Chapter’s Overview...12
CHAPTER 2 LITERATURE REVIEW...13
2. 1. FESTO Modular Production System...13
2. 2. Programmable Logic Controller...13
2. 3. Microcontroller...15
2. 4. Human Machine Interface...16
2. 5. Supervisory Control and Data Acquisition (SCADA)...17
2. 6. Communication Protocols...21
2. 6. 1...RS- 232 22 2. 6. 2...RS- 485 25 2. 6. 3...Wind ows Dynamic Data Exchange (DDE)...30
2. 6. 4...Siem ens PPI-MPI...30
Alfred Masadhi Selo
CHAPTER 3 METHODOLOGY...31
3. 1. System Design Overview...31
3. 2. Description...32
3. 2. 1...Distri bution Station...32
3. 2. 2...Testi ng Station...32
3. 3. I/O Configuration and tag assignments...33
3. 4. Solution...38
3. 4. 1...Direc t link using microcontroller...38
3. 4. 2...MPI link using Simatic WinCC® V6.2...39
CHAPTER 4 RESULTS AND DISCUSSION...40
4. 1. Prepare the experiment board...41
4. 2. Setting the PLC program...41
4. 3. Creating a project...42
4. 4. Setting up the communication to the PLC...43
4. 5. Creating tags...45
4. 6. Creating graphics element...49
4. 7. Manipulating graphics element...58
4. 8. Executing the runtime...66
4. 9. Process Windows...67
4. 10. Global Scripts...70
4. 11. DDE application...72
4. 12. Setting DDE communication in WinCC...73
4. 13. Microcontroller...75
CHAPTER 5 CONCLUSION AND RECOMMENDATION...76
APPENDIXES...77
A. REFERENCES...77
B. Datasheets...78 C. Bill of Materials...84
CURRICULUM VITAE...85
Alfred Masadhi Selo
