Journal of Mechatronics, Electrical Power and Vehicular Technology ISSN 2087-0116

Vol. 0, No. 0, Juli 2010 SK No: 13/AKRED/LIPI/P2MBI/3/2011

FRAMEWORK OF FLEXIBLE MANUFACTURING SYSTEM (FMS)

FOR EDUCATION BASED ON MICROCONTROLLERS AND
FIELDBUS
Arko Djajadi, Tutuko Prajogo, Maralo Sinaga
Department of Mechatronics,
Faculty of Engineering
Swiss German University
Campus German Centre, Bumi Serpong Damai
Tangerang 15321
Phone/Fax: (021)-537 6221 / 537 6201
Email: arko@sgu.ac.id, maralo.sinaga@sgu.ac.id, tutuko.prajogo@sgu.ac.id

Abstract

Swiss German University has excellent FMS laboratory facility based on FESTO products. However, the
facility is limited in quantity and could not be extended easily due to the relatively high cost for extending the
facility. Consequently, the objectives of preparing students to gain real world industrial automation and the
use of laboratory facility are not optimized. In this paper a framework of an FMS for education based on
microcontrollers and fieldbus is presented. Microcontrollers are chosen due to their widespread availability,
low cost and versatility. Fieldbus is implemented by customizing existing standard bus systems such as
Modbus and Profibus, thus providing hand-on experience and control of the communication bus system. The
framework can thus strengthen the pedagogical to the students and at the same time the functionality of the
laboratory facility can be extended. Existing facility and new equipments can then be combined together as a
network, thus creating a customized FMS. Each new functional part can be developed by a group of students
according to the requirement and an agreed standard fieldbus protocol. After successfully tested
independently, each new part can then be connected to the network to forms a new node in the FMS. The
end result is a really flexible and extendable manufacturing system. The objective of extending laboratory
facility and exposing students to real world applications are thus realizable.

Keywords : Flexible Manufacturing System, Manufacturing Automation, System Design,

Microcontroller, Fieldbus

1. Architecture of FMS deals with process management and control

Before discussing SGU FMS, a typical system at cell level. A gateway to the next
FMS architecture will be used as a reference level is provided.
for the next sections [1,2,3]. Five layers can The fourth level is the field level where
be defined as depicted in Figure 1. fieldbus is used to interconnect elements at
The top level is the first level that deals this level, and where actual smart actuators
with planning activities within a and sensors are attached. The fifth level can
manufacturing unit. As the amount of data be added for specific applications.
communicated at this level is normally high, it
typically involves many computers, equipped
with Ethernet cards. These computers are
interconnected by means of a high speed
internet/intranet infrastructure. A gateway is
used to connect this level to the second level.
The second level is control level that
performs production control, where each
production unit is connected to each other
through a fieldbus network, such as Profibus-
FMS. A gateway is in place to connect this
level to the third level.
The third level is cell level, where each
part is connected trough a fieldbus. This level Figure 1. Model of factory control levels [1,2,3]

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 Framework of Flexible Manufacturing System (FMS) for Education Based on Microcontrollers and Fieldbus
(Arko Djajadi)
A possible network for different levels of
control can be summarized as in Figure 2
[1,2], including some sample nodes on their
respective networks. At the top level the
concern is fast and high capacity data
communication, utilizing high speed medium
typically 100 MBit/s or above. On the
contrary, at the bottom level where sensors
and actuators are attached, the amount of data
communicated is low, but its timing is very
critical. Here the data exchange must be in
real time to allow the actuators to react
instantly based on the sensors outputs.
Figure 2. Network on the different levels of a
factory [1,2,3]
2. Existing FMS Laboratory
There are two working systems available at
the SGU for students to learn about FMS,
namely Modular Processing System (MPS)
and Flexible Manufacturing System (FMS),
both of them are FESTO products. Below is
the description of both.
2.1 Modular Processing System (MPS)
The first is Modular Processing System
(MPS). This system is used extensively in the
automation technology learning processes.
Each part can be disassembled, assembled
back, programmed, tested and integrated as
required. The students are assigned such tasks
from time to time.
2.1.1 Stations
In this MPS, four stations are connected
together to accomplish a typical automated
manufacturing processes in a small scale.
Each station is controlled by its own master
PLC but without SCADA. The station names
are distribution, testing, processing and robot
handling.
20
Distribution Testing Processing Robot Handling
Station Station
Station Station
PLC PLC PLC PLC
Figure 3. MPS stations with PLCs and inter
PLC I/O communication
2.1.2 PLC-based Controlling and Direct I/O
Networking
The MPS is controlled directly by PLCs. As
there are four stations, four PLCs are required
for complete control. Input/output information
exchange between stations is accomplished by
passing certain PLC output bits from one
station to the input bits of next or previous
station. As the distance is short, this method
works well. In this way, there is no true
networking involved. Option is available for
this MPS to be networked with Profibus, as
has been done, by replacing three PLCs,
except the first one, with three extended I/O
cards having profibus interfaces.
2.1.3 Operation
The MPS works on pieces of tubes or piston
housings that are taken from a magazine in the
distribution station. It incorporates some
sensing elements and electro-pneumatics
actuators controlled by a PLC.
From the distribution station, the
workpiece is transferred to the testing station
to test its color and its acceptable size. Color
identification is done by optical, inductive and
capacitive sensors together, as the final
processing later will be grouped according to
the workpiece color. If the size matches and
its color has been determined, the workpiece
is ready for next processing in the processing
station or otherwise rejected.
In the processing station, the workpiece is
subsequently placed in a rotary table, sent to a
drilling unit for creating a hole, sent to an
inspection unit for final checking. The robot
handling station is then signaled that the
workpiece is ready for storage.
In addition to workpiece readiness status,
information about its color are also passed to
the robot handling. Finally the robot picks the
workpiece up and stores it in the correct
location based on its color. Then the process
is repeated from the start until the magazine is
empty.
Journal of Mechatronics, Electrical Power and Vehicular Technology
Vol. 0, No. 0, Juli 2010
2.2 Flexible Manufacturing System (FMS)
The second is Flexible Manufacturing System
(FMS) with SCADA. This FMS is used
mostly for demonstrating what normally
happens in more automated systems with
higher degree of complexity than the MPS.
2.2.1 Stations
In addition to four stations existing in the
MPS, in this FMS there are automatic storage
and retrieval station (ARS), magazine stock
manager, conveyor and two PCs for the
SCADA. They are controlled by a network of
PLCs linked with Profibus to accomplish
typical automated manufacturing processes in
a larger and much more complex scale, as
shown in Figure 4. Each station is controlled
by its own PLC, but all PLC are mastered by
the SCADA PC. It is also possible for each
station to work independently on its own, in
which each PLC is acting as the master.
Master Robotic
Distribution Testing Assembly
SCADA Station Station Processing
Station
PLC PLC PLC
PLC
Profibus
PLC
Slave
SCADA
ARS Conveyor
Station Station
Figure 4. Existing FMS stations
2.2.2 Profibus-based Controlling and
Networking
Profibus is a fieldbus standard developed
in a joint research project in 1987. In 1991,
DIN 19245 was adopted, whereby the
Profibus became one of the first standardized
fieldbus systems. This is an open fieldbus
standard covering a wide area within process
and building automation [1,2,3].
This more advanced FMS has many
stations and each station is controlled directly
by a dedicated PLC. Networking is done by
means of Profibus system to allow advanced
integration with SCADA on two dedicated PC
ISSN 2087-0116
SK No: 13/AKRED/LIPI/P2MBI/3/2011
workstations running SCADA Software for
graphical monitoring and control of all
stations.
2.2.3 Operation
How the FMS operates will be
summarized below. After initializing all
stations, the FMS is ready for operations.
Depending on the task assigned by the
operator from the master SCADA PC, the
FMS will perform different operations. Here,
for example the task is to assemble a set of
four pieces of finished pistons consisting of a
housing, spring, piston and locking cover.
Upon a start command, a set of 4 piston
housings is retrieved automatically by a
dedicated ARS from the storage area
maintained by a dedicated stock manager.
The set is placed on a carrier on the conveyor
ready to convey it to the processing stations.
The carrier stops exactly in front of the
processing station, where the handling robot
of the processing station lifts the full carrier to
a designated place.
The handling robot hand smartly takes
single piston housing and places it in a
clamped position. Subsequently the handling
robot adds a piston, a spring, and lastly a
locking cover that are taken from their
respective storage or stacks. The robot hand
presses and twists the locking cover on the
assembly and a final piston system is
produced and placed back on the original
carrier. The other three piston housings are
treated similarly until four completed pistons
are obtained.
The full carrier is then lifted, moved and
placed back on the conveyor. The conveyor
brings the full carrier to the ARS who will
store the final product in the storage area
based on the information from the stock
manager PC. In this example, as the
component to be assembled is from storage
area, the distribution and testing stations are
idle unless instructed otherwise.
3. Extended FMS
Based on the available MPS and FMS systems,
an extended FMS version is developed to
support the practical teaching and learning
process.
3.1 Purpose
The purpose of developing extended FMS
is to utilized the four MPS stations except
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 Framework of Flexible Manufacturing System (FMS) for Education Based on Microcontrollers and Fieldbus
(Arko Djajadi)
their PLCs, add other relevant processing
stations, integrate all of them by means of a
serial bus / fieldbus network and complete the
whole system with SCADA capability.
Networking with fieldbus will simplify wiring
between stations. The main drive is to have a
testbed to experiment open-endedly and to use
low cost microcontrollers as the brain of each
node, without risking of damaging the
existing FMS.
3.2 Microcontroller as Controlling and
Networking Elements
The extended FMS is based on
microcontrollers which will function as the
smart nodes controlling sensors and actuators
attached to them. On the other hand the
microcontrollers with their built-in serial port
are equipped with RS232-to-RS485
converters to allow multipoint-connection and
thus creating a simplified fieldbus network.
Figure 5 illustrates such network.
Figure 5. Master/slave system in a simplified
fieldbus network
3.3 Components
The main components of the extended FMS
will be explained below. Starting with some
necessary inhouse developed add-ons, such as
FMS protocol simulator, serial converter and
protocol converter, the 8 stations of extended
FMS are discussed.
3.3.1 Inhouse Developed Add-Ons
Before the extended FMS can be realized,
there are a number of issues that must be
solved first. Each of the issue will be
discussed.
3.3.1.1 FMS Protocol Simulator
Before really starting the projects to build
the whole system of an extended FMS, the
first step is to build and test the protocol and
22
network that will be used later. Tutuko
Prayogo and Bambang Darwis created the
first FMS Simulator using Microsoft Visual
Basic to support the Automation Technology
lecture and laboratory.
By networking PCs through its serial port
equipped with RS232-to-RS485 converter,
each PC is thus physically connected to other
PCs along a segment of serial cable. The FMS
Simulator is then run on each PC, one acting
as the master node while the rest acting as the
slave nodes.
3.3.1.2 RS232 to RS485 Converter Card
RS232 is a serial, bi-directional,
asynchronously operating interface. It
operates with a signal level against ground
and is therefore relatively interference-prone
(distances of up to 30 m). RS232 is not
designed to communicate data by more than
two stations.
Therefore, to allow multipoint
connections RS485 is used. To do so, a
converter card from RS232-to-RS485 is built.
By using a number of converter cards,
simplified fieldbus network can be realized.
The RS485 is the most widely used
hardware for fieldbus systems. It defines a
line with a maximum of 32 stations, restricted
by bus terminating resistors at both ends.
Originally it defined a data transfer rate of up
to 500 kBit/s. In the meantime, up to
12MBit/s are now realized. Depending on the
data transfer rate, distances are between
approximately 1200 m and 200 m.
The RS485 operates using twisted and
screened data transfer lines. The twisted line
(also known as ‘twisted pair’) consists of a
pair of wires, which is twisted like a string.
The purpose of this is to ensure that electrical
interference affects both wires simultaneously.
If both wires are floating-ground or of
identical potential to ground then such a
system is highly insensitive to interference, as
the signal is measured in the form of a
differential voltage signal irrespective of
ground
3.3.1.3 Protocol Converter Card
Another problem arose when trying to
integrate the 6 DOF robot handling station to
the network, as it is controlled by its
proprietary on-board computer. Interfacing to
it must be accomplished through serial port,
which is normally used to upload/download
Journal of Mechatronics, Electrical Power and Vehicular Technology ISSN 2087-0116
Vol. 0, No. 0, Juli 2010 SK No: 13/AKRED/LIPI/P2MBI/3/2011

coordinate values and instructions to/from PC. remove the workpiece from the processing
This problem is solved by designing a special station and place it on the orientating station.
protocol converter card that translates and The orientating stating will check whether the
encapsulates each packet traveling in the workpiece is upside-down or not. If so, it will
fielbus network to/from the robot handling be rectified.
station. Once the checking and orientating
operations are completed, the workpiece is
3.3.2 Stations placed on a carrier parking on the conveyor
As already stated in the purpose above, the belt. The SCADA PC then gives orders to the
idea is to create extended FMS based on MPS. conveyor station to carry the workpiece to the
There are 8 stations, and their names are designated point, from which the workpiece
distribution, testing, processing, robot will be taken away and stored in the ARS
handling[4], orientating[5], conveyor[6], station. The cycle is then repeated from the
ARS[7] and SCADA[8] stations. beginning under the control of the master
SCADA PC.
Master
Distribution Testing Processing
Robotic All communication is thus performed
SCADA Handling
Station Station Station Station along the fieldbus. The packet conversion
from RS232 format, when the packet leaves
the each node, to RS485 format is done by
RS232-to-RS485 converter attached to each
uC uC uC uC
node.
fieldbus As mentioned earlier, a special
uC uC uC
microcontroller-based protocol converter is
developed to allow the robot handling station
to be configured as a separate node, since this
station has its own proprietary built-in Zilog-
ARS Conveyor Orientating
Station Station Station based computer [9]. It accepts special robotic
commands, such “NT” for nesting or “RS” for
Figure 5. Extended FMS stations
reset, and returns specially formatted response,
which must be encapsulated correctly before
All stations are treated as nodes, assigned
transferring it in the fieldbus network. Each
unique station IDs and integrated on a
packet must be formatted to have an ID,
segment of serial bus network.
function code, data and CRC to allow correct
Microcontrollers are the brain of each node
addressing, instruction and error checking.
except the SCADA which is a PC, thus
One of the stations, the master, controls
creating a microcontroller-based fieldbus
bus access by issuing a time limited send
network.
authorization cyclically to the other stations,
i.e. the slaves. With a master/slave system,
3.4 Operations only the master has control over the bus. All
The operation of the extended FMS for the other stations, the slaves, must continually
the first three workstations (distribution, listen to the bus and can only send data via the
testing, processing) is similar to the original bus following a request by the master.
MPS described earlier. The difference is that
now these three stations are no longer
4. Lesson learned
controlled by 3 master PLCs, but by a single
Briefly will be discussed the valuable
slave microcontroller. This slave
lesson learned from developing the extended
microcontroller is functioning as one of the
FMS.
node with a unique address in a fieldbus
network, mastered by a PC designated as the
4.1 Practical Learning Process
SCADA station.
The effort has benefited tremendously to
Upon the completion of the operation in
everyone involved in the projects. It improves
the first three stations, a ready status is sent by
considerably both theoretical and practical
the slave node that controls these three
knowledge that is highly valued in
stations to the SCADA PC. The SCADA PC
mechatronics learning processes. Many
then instructs the robot handling station to
subjects learned in the classes and labs, such

23
 Framework of Flexible Manufacturing System (FMS) for Education Based on Microcontrollers and Fieldbus
(Arko Djajadi)
as microcontroller and automation, are put [2].
into practice in solving both challenging and
rewarding real life industrial problem.
4.2 What next? [3].
As the main objective to create a
framework of FMS has already been achieved, [4].
the next step is to improve its reliability,
functionality and flexibility that are still weak
in the first version. This is an ongoing effort
in parallel with the learning process that is
expected to benefit everyone involved. [5].
5. Conclusion
A framework of an FMS for education
based on microcontrollers and fieldbus has
been developed and presented. [6].
Microcontrollers are chosen due to their
widespread availability, low cost and
versatility. Fieldbus is implemented by
customizing existing standard bus systems [7].
Modbus. The end result is a really flexible and
extendable learning system with modular
approach under the same control through a
standard fieldbus network. The objective of [8].
extending laboratory facility and exposing
students to real world applications are thus
realizable.
[9].
References
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“Fieldbus technology AS-Interface”,
FESTO Workbook TP 401 Denkendorf,
Germany, 2003
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Monika Bliesener, Sabine Scharf,
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Germany, 2003
Jonas Berge, “SMAR The Fieldbus
Book”, Year 2002 edition
Avioko Leksiantoro, “ Test and
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Manufacturing System”, Thesis Report
in Mechatronics Department SGU,
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Sandy Budiman, “ Prototype of a Disk
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ATMEGA16 Microcontroller”, Thesis
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SGU, 2005
Sugianto, “ Prototype of a Conveyor
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Microcontroller”, Thesis report
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