Logistics Gate with SIMATIC RF600

Transcription

1 Application Example 07/2015 Logistics Gate with SIMATIC RF600 RF600 / Windows application

2 Warranty and Liability Warranty and Liability Note The application examples are not binding and do not claim to be complete with regard to configuration, equipment or any contingencies. The application examples do not represent customer-specific solutions. They are only intended to provide support for typical tasks. You are responsible for the correct operation of the described products. These application examples do not relieve you of the responsibility of safely and professionally using, installing, operating and servicing equipment. When using these Application Examples, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these application examples at any time and without prior notice. If there are any deviations between the recommendations provided in this Application Example and other Siemens publications e.g. Catalogs the contents of the other documents shall have priority. We do not accept any liability for the information contained in this document. Any claims against us based on whatever legal reason resulting from the use of the examples, information, programs, engineering and performance data etc., described in this Application Example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act ( Produkthaftungsgesetz ), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of fundamental contractual obligations ( wesentliche Vertragspflichten ). The compensation for damages due to a breach of a fundamental contractual obligation is, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. The above provisions do not imply a change of the burden of proof to your detriment. Any form of duplication or distribution of these application examples or excerpts hereof is prohibited without the expressed consent of Siemens AG. Security information Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens products and solutions undergo continuous development. Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party products that may be in use should also be considered. For more information about industrial security, visit To stay informed about product updates as they occur, sign up for a productspecific newsletter. For more information, visit Entry ID: , V1.0, 07/2015 2

3 Table of Contents Table of Contents Warranty and Liability Task Overview Requirements Solution Overview Description of the core functionality Hardware and software components Validity Components used Mode of Operation General overview Data traffic Handling frames Installation and Commissioning Installing the hardware Installing the software Commissioning Configuring the SIMATIC RFID Reader Operating the Application Example Connect to the reader Managing Delivery Note and Read Transponder Automatic gate operation Manual gate operation Links & Literature History Entry ID: , V1.0, 07/2015 3

4 1 Task 1 Task 1.1 Overview Introduction For reliable registration of incoming and outgoing goods at a logistics gate, you need a powerful RFID system. The SIMATIC RFID system RF600 convinces through its performance, high quality and efficient realization options in the IT and automation environment. Especially logistics applications require simple IT integration. In addition, the readers offer easy configuring and diagnostics via a web interface. This application example describes the IT integration of the SIMATIC RFID system RF600. Integration and mode of operation are shown using a logistics gate. Overview of the automation task The figure below provides an overview of the automation task. Figure 1-1 Goods w ith RFID transponders RFID reader Transponder data Management softw are Description of the automation task A gate has an RFID reader installed. Its function is to acquire all incoming and outgoing goods with transponders. This application example is controlled by a Windows PC, and acquired transponders are displayed in a table in a simple management software. The central automation device is the SIMATIC RFID Reader RF680R. Entry ID: , V1.0, 07/2015 4

5 1 Task 1.2 Requirements Requirements of the automation task This application example shall be realized with just one RFID reader. The RFID reader shall be integrated to the higher-level IT system via Ethernet (TCP/IP). The management program shall be clearly arranged and able to run on standard Windows systems. The transponder data shall be exported so that they can be integrated into existing office applications (e.g. Microsoft Excel). The digital inputs of the RFID reader shall evaluate proximity sensors. The digital outputs of the reader shall control a light column. Entry ID: , V1.0, 07/2015 5

6 2 Solution 2 Solution 2.1 Overview Schematic layout The figure below shows a schematic overview of the most important components of the solution: Figure 2-1 SIMATIC RF680R Windows PC with management software Industrial Ethernet DI/DO cable Antenna cable Gate with 4x SIMATIC RF640A, proximity sensors and light column Advantages Easy and quick commissioning Time and cost savings due to the SIMATIC RFID reader as a central automation component. Topics not covered in this application This application does not contain a description of high-level language programming and logistics requirements. Basic knowledge of these topics is assumed. Entry ID: , V1.0, 07/2015 6

7 2 Solution User interface of the management software The figure below describes the user interface of the management software: Figure Connection parameters: IP address of the reader, name of the read point and selection of reader type 2. Table for the delivery note: The expected goods or transponders ( EPC-ID ) and their direction ( Direction ) are entered here. 3. Options for the delivery note table: Clear, import and export. 4. Table for the read transponders: The read goods or transponders ( EPC-ID ) and their direction ( Direction ) are entered here. 5. Options for the table of read transponders: Clear and export. 6. Options for the general gate operation: Use the Use IO sensors/ deactivate permanent reads check box to toggle between automatic and manual reading. If you want to activate manual reading, you have to specify the direction of the goods ( Direction: in and Direction: out ). 7. Use the EPC-ID in ASCII format check box to toggle between Hex and ASCII view of the EPC-IDs. 8. Reset reader reboots the reader WBM opens the Web Based Management of the reader. 10. Info opens an info window of the management software of the reader. Entry ID: , V1.0, 07/2015 7

8 2 Solution 2.2 Description of the core functionality Sequence of the core functionality Figure 2-3 Enter connection data Connect/ start Close connection/stop Send data to reader No Waiting for new reader telegrams. Relevant data? Evaluate/ process data Yes Show data After the management software has set up the connection with the SIMATIC RFID Reader, the logistics gate is active. The reader detects incoming or outgoing goods and automatically starts RFID data readings to read the transponders attached to the goods. After transponder data have been read, the reader transmits them to the management software. The evaluation of the data is done by the management software. Two tables are used in the management software. One table contains the delivery list with the expected transponders, the second table contains the actually read transponders. Both tables are compared to be able to show the user how far his delivery list has been processed. Entry ID: , V1.0, 07/2015 8

9 2 Solution 2.3 Hardware and software components Validity This application is valid for Windows 7/8 x86/x64 Internet Explorer (from version 10).NET Framework 4 or higher Components used The application was created with the following components: Hardware and software components Table 2-1 Component Qty Article number Note SIMATIC RF680R 1 6GT2811-6AA10-0AA0 A SIMATIC RF650R can be used alternatively. SIMATIC RF640A 4 6GT2812-0GA08 SIMATIC RF640T n 6GT2810-0DC00 Other RF600 transponders can be used alternatively. Antenna plug-in connection 24 V connection cable 5m Wide-range power supply unit for SIMATIC RF systems 4 6GT2815-2BH50 1 6GT2891-0PH50 Cables of different lengths can be used alternatively. 1 6GT2898-0AA00 Ethernet cable 1 With M12 or RJ45 plug, depending on the reader Proximity sensors 2 Optional Suitable for optical or sonar sensors Light column 1 Optional The application example uses a three-stage light column Example files and projects The following list includes all files and projects that are used in this example. Table 2-2 Component Note _RF600_PC_CODE_v10.zip This zip file contains the Visual Studio project _RF600_PC_EXE_v10.zip This zip file contains the executable Windows application _RF600_PC_DOKU_v10_en.pdf This document. Entry ID: , V1.0, 07/2015 9

10 3 Mode of Operation 3 Mode of Operation 3.1 General overview General principle of operation Figure 3-1 Proximity sensors Light column Transponder SIMATIC RFID Reader Windows PC Windows application (management software) Ethernet TCP/IP Radio The SIMATIC RFID Reader serves as a central interface of the components used in this application example. The proximity sensors are connected to the DI ports of the SIMATIC RFID reader. This enables the reader to directly forward the proximity sensor DI signals via its XML interface. When a DI port registers a signal edge, the reader sends this information to the Windows application via XML. The Windows application takes up the signal and evaluates which of the DI ports has received a signal. Using this differentiation, the management software can detect whether goods are coming in or going out through the gate. Simultaneously, the management software starts an RFID reading with an XML command. Entry ID: , V1.0, 07/

11 3 Mode of Operation When the reader detects transponders in his field while reading, it reads the EPC- ID (Electronic Product Code) of the transponder and sends it to the management software via XML as a TAG event. The management software then compares the received EPC-IDs with a list imported beforehand (delivery list) which contains the expected transponders and adds them to the table for read transponders. At the same time, the entry in the imported list is marked to indicate that an expected transponder has passed the gate. The light column is connected to the DO port of the SIMATIC RFID reader. The management software sends XML commands for light column control to the reader. The light column indicates the status of the RFID gate in this application example. 3.2 Data traffic Data traffic between the Windows PC and the SIMATIC RFID reader happens via Ethernet TCP/IP. This is achieved by exchanging XML command and response frames between the management software and the reader. The reader can send asynchronous frames for specific events. The XML frames have a specific pre-defined structure. Further information is available in the manual RFID Systems SIMATIC RF650R/RF680R/RF685R (\3\) in chapter 8 XML interface. Figure 3-2 Windows PC Ethernet TCP/IP SIMATIC RF680R XML The XML frames from the management software are created with class RFID_CMD. This class returns XML command strings for RFID reader control. The following sample code shows the XML command structure for the registration at the reader. <frame> <cmd> <id> value_id </id> <hostgreetings> </hostgreetings> <readertype> readertype </readertype> <supportedversions> <version> value_version </version> </supportedversions> Entry ID: , V1.0, 07/

12 3 Mode of Operation </frame> </cmd> This XML command is sent to the reader via a TCP connection as a byte array. The following response frame is transmitted by the reader in case of a registration attempt: <frame> </frame> <reply> </reply> <id> value_id </id> <resultcode> resultcode </resultcode> <hostgreetings> <returnvalue> <version> value_version </version> <configid> value_configid </configid> </returnvalue> </hostgreetings> If resultcode returns the value 0, the reader has accepted the registration of the client. 3.3 Handling frames The core of the management software consists of a AsyncCallback method. The data required for the AsyncCallback method are taken from the NetworkStream with the BeginRead method. The networkstream is the connection between the management software and the RFID reader. The RFID reader reacts to events and sends them to the management software via the NetworkStream. tageventreports (transponder events), ioeventreports (changes at the digital reader inputs or outputs) and Alarms (fault messages) are recorded. The data taken is converted to strings to simplify evaluation. Unlike the reports sent from the reader, the management software sends simple command frames to the reader. Command Frames Each command frame from the management software is acknowledged by the reader with a response frame. The following command frames are used in this application example and are generated as RFID_CMD class: hostgreeting: Software log in at the reader hostgoodbye: Software log out from the reader heartbeat: Cyclic monitoring of the data connection to the reader triggersource: Start/stop EPC-ID reading of transponders resetreader: Reboots the reader setio: Sets the digital outputs of the reader Entry ID: , V1.0, 07/

13 3 Mode of Operation Further information on command frames is available in the manual RFID Systems SIMATIC RF650R/RF680R/RF685R (\3\) in chapter 8 XML interface. Evaluation of asynchronous frames (events) They, too are evaluated based on the string structure. The following criteria are used for evaluation: Completeness of the string: The string must contain <frame> and </frame>. ioeventreport: In addition to completeness, it is also checked whether it is an ioeventreport. The string must contain <ioer> and </ioer>. Using the ioeventreports it is determined whether a reading must be started or stopped and the direction in which the goods pass the gate. tageventreport: In addition to completeness, it is also checked whether it is an tageventreport. The string must contain <ter> and </ter>. If this is the case, the read EPC_ID of the transponder which is transmitted with this event can be written in a management software table. Alarm: In addition to completeness, it is also checked whether it is an alarm. The string must contain <alarm> and </alarm>. Depending on the alarm, the management software outputs the respective error message. Entry ID: , V1.0, 07/

14 4 Installation and Commissioning 4 Installation and Commissioning This chapter describes the steps necessary to commission the application. 4.1 Installing the hardware The figure below shows the hardware configuration of the application. Figure 4-1 PROFINET IE Antenna line/power supply Wide-range power supply unit SIMATIC RF680R Light column SIMATIC RF640A Proximity sensors Note You must always follow the installation guidelines for SIMATIC RFID Readers. 1. Connect the SIMATIC RFID reader (port X80) to the wide-range power supply unit. 2. Connect the SIMATIC RF antennas (port Ant1 - Ant4) to the reader. 3. Connect the SIMATIC RFID reader (port X1) to a PC via Ethernet. 4. (Optional) Connect the proximity sensors to the SIMATIC RFID reader (port X10). Take note that the sensor for incoming goods must be connected to Inport00 and the sensor for outgoing goods must be connected to Inport (Optional) Connect the (three-level) light column to the SIMATIC RFID reader (port X10). Take note that the light column is connected to Outports 00, 01 and Plug the wide-range power supply unit into a suitable socket outlet. Further information on connecting the reader are available in the SIMATIC Ident RFID systems SIMATIC RF600 System Manual (\4\) in chapter 5 Reader. Entry ID: , V1.0, 07/

15 4 Installation and Commissioning 4.2 Installing the software This chapter describes the steps for the installation of the example program. 1. Download the program from the HTML page of this entry (\2\). 2. Unzip the program. 4.3 Commissioning This chapter describes the steps for the commissioning of the example program. 1. Start the demo program by double-clicking the RF600_Gate.exe. 2. Assign an IP address for the RFID reader (via PCT, STEP 7 or TIA Portal). 3. Enter the connection data in the respective fields, see chapter Connecting to the reader. 4. Click on Connect. 5. The gate can be passed through now. Entry ID: , V1.0, 07/

16 5 Configuring the SIMATIC RFID Reader 5 Configuring the SIMATIC RFID Reader This chapter describes the steps necessary to configure the modules of this application for the automation solution. 1. Start the Web Based Management (WBM) of the SIMATIC RFID reader. Open an internet browser and enter the IP address of the reader into the browser s address bar. Alternatively, you can start the management software and enter the reader s IP address there and then click on WBM. 2. In the WBM, go to Settings -> Read points, create a read point with four (or less) antennas and assign it a name (e.g. Readpoint_1 ). Download the configuration to the reader. Figure In the WBM, go to Communication. Make sure that the standard setting secured transmission is not checked. For this demo application, the check boxes event type Observed, data event and IO events Enable must be selected. Download the configuration to the reader. Figure 5-2 Entry ID: , V1.0, 07/

17 5 Configuring the SIMATIC RFID Reader 4. See Links & Literature RFID Systems SIMATIC RF650R/RF680R/RF685R (\3\) for further configuration options like transmission power settings or antenna orientation. Entry ID: , V1.0, 07/

18 6 Operating the Application Example 6 Operating the Application Example This chapter describes the operation of the management software. 6.1 Connecting to the reader 1. Enter you SIMATIC RFID reader s IP address in the IP address field. 2. Enter the name of the read point you have configured in the Readpoint field. Please ensure correct upper and lower case. 3. Select the reader type used by you from the list Reader type selection. 4. Click on Connect. 5. When the Connect button is grayed out, you have successfully established a connection to the reader. Figure Managing Delivery Note and Read Transponder tables Manual input of transponders (only for Delivery Note) The Delivery Note instructs the management software which transponders shall pass the gate. You can enter EPC-ID and Direction. Make sure that the EPC- IDs entered conform to the selected format. When the EPC-ID in ASCII format check box is activated, you can use all ASCII characters. When the check mark not set, you can use only HEX-coded strings. Importing transponder lists (only for Delivery Note) Additionally, you can also import pre-made XML tables. You can create these, for example, in Microsoft Excel and save them in XML format. These XML files can then be imported to the management software with the Import button. When creating lists for import, make sure the column headers have exactly the same name as displayed in the management software. In addition, make sure that the EPC-IDs entered conform to the selected format. When the EPC-ID in ASCII format check box is activated, you can use all ASCII characters. When the check mark not set, you can use only HEX-coded strings. Entry ID: , V1.0, 07/

19 6 Operating the Application Example Exporting transponder lists You can export your Delivery Note and the Read Transponder with the Export button. The data will be saved as an XML file which can easily be opened in Office programs and converted to a table. Deleting transponder lists When the processing of a delivery note is complete, you can delete the tables with the Clear button independent of the gate operation. 6.3 Automatic gate operation After having connected to the reader, automatic gate operation is active. This means that the gate will automatically detect (with the proximity sensors) incoming goods and their direction. In doing so, readings are automatically started and stopped. The read transponders are written in the respective Read Transponder table and compared with the delivery note. When two transponders in EPC-ID and Direction match, they are marked as Assigned in both tables and are marked with a color in the delivery table. If a read transponder cannot be assigned, it is marked red in the table of read transponders. In automatic gate operation, a reading is stopped automatically after 60 seconds as not to trigger continuous readings in case an object is moved in the gate area unintentionally. The user must only manage these two tables during operation. Figure 6-2 Entry ID: , V1.0, 07/

20 6 Operating the Application Example 6.4 Manual gate operation Enable manual gate operation by unchecking the Use IO sensors/ deactivate permanent reads check box. In this mode, the reader is continuously reading. No distinction is made if they are going in or coming out of the gate. In this case, the user must specify the direction with the control boxes Direction: In (incoming) And Direction: out (outgoing). This mode is only recommended if you use the gate without sensors or for manually entering transponders. The read transponders are written in the respective Read Transponder table and compared with the delivery table. When two transponders in EPC-ID and Direction match, they are marked as Assigned in both tables and are marked with a color in the delivery table. If a read transponder cannot be assigned, it is marked red in the table of read transponders. The user must manage these two tables and the direction of the goods ( Direction check box) during operation. Figure 6-3 Entry ID: , V1.0, 07/

21 7 Links & Literature 7 Links & Literature Table 7-1 Topic \1\ Siemens Industry Online Support \2\ Download page of the entry \3\ SIMATIC Ident RFID Systems SIMATIC RF650R/RF680R/ RF685R \4\ SIMATIC Ident RFID systems SIMATIC RF600 System Manual Title History Table 8-1 Version Date Modifications V1.0 07/2015 First version Entry ID: , V1.0, 07/