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| − | <translate>= Permanent Problems = | + | <translate>=Permanent Problems= |
| + | Permanent problems are issues that are permanently there until you solve them. For instance, the emergency stop circuit will not reset, but there is no indication why. | ||
| − | === | + | ===Check the EtherCAT circuit=== |
| + | See See [https://stuga.dokit.app/wiki/Diagnosing_EtherCAT_Issues_-_Advanced Diagnosing EtherCAT Issues] - Advanced to see if there is a permanent break in the etherCAT circuit, as this will also stop the emergency stop resetting | ||
| − | = Intermittent problems = | + | ===Navigating the Safety Function Blocks=== |
| + | If you cannot see what is stopping estop working, you can take a look at the internals of the safety function blocks using the online view. | ||
| + | |||
| + | Firstly, get the TwinSafeGroup open | ||
| + | <br />{{#annotatedImageLight:Fichier:Diagnosing TwinSAFE Issues - Advanced Image 1.png|0=409px|hash=|jsondata=|mediaClass=Image|type=frameless|align=center|src=https://stuga.dokit.app/images/3/3d/Diagnosing_TwinSAFE_Issues_-_Advanced_Image_1.png|href=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 1.png|resource=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 1.png|caption=|size=409px}} | ||
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| + | The function block screen can be zoomed in and out to show you more of it, and you can scroll round with the scroll bars{{#annotatedImageLight:Fichier:Diagnosing TwinSAFE Issues - Advanced Image 2.png|0=400px|hash=0328ba9df3e1dd8681980d72ad4e3823|jsondata={"version":"2.4.6","objects":[{"type":"image","version":"2.4.6","originX":"left","originY":"top","left":0,"top":0,"width":1030,"height":1012,"fill":"rgb(0,0,0)","stroke":null,"strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":0.39,"scaleY":0.39,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"crossOrigin":"","cropX":0,"cropY":0,"src":"https://stuga.dokit.app/images/7/71/Diagnosing_TwinSAFE_Issues_-_Advanced_Image_2.png","filters":[]},{"type":"wfarrow2line","version":"2.4.6","originX":"center","originY":"center","left":317,"top":353.5,"width":136,"height":29,"fill":"rgba(255,0,0,0)","stroke":"#FF0000","strokeWidth":4,"strokeDashArray":null,"strokeLineCap":"round","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1,"scaleY":1,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"x1":-68,"x2":68,"y1":-14.5,"y2":14.5,"x2a":50.10812615133858,"y2a":2.5049656030678307,"x2b":46.77137797377472,"y2b":18.153163953022506},{"type":"wfarrow2circle","version":"2.4.6","originX":"center","originY":"center","left":249,"top":339,"width":16,"height":16,"fill":"#aaa","stroke":"#666","strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1,"scaleY":1,"angle":0,"flipX":false,"flipY":false,"opacity":0.5,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"radius":8,"startAngle":0,"endAngle":6.283185307179586},{"type":"wfarrow2circle","version":"2.4.6","originX":"center","originY":"center","left":385,"top":368,"width":16,"height":16,"fill":"#aaa","stroke":"#666","strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1,"scaleY":1,"angle":0,"flipX":false,"flipY":false,"opacity":0.5,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"radius":8,"startAngle":0,"endAngle":6.283185307179586},{"type":"textbox","version":"2.4.6","originX":"center","originY":"center","left":213,"top":336,"width":51.12,"height":22.6,"fill":"#FF0000","stroke":"#FF0000","strokeWidth":1,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1,"scaleY":1,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"text":"Zoom","fontSize":20,"fontWeight":"normal","fontFamily":"sans-serif","fontStyle":"normal","lineHeight":1.16,"underline":false,"overline":false,"linethrough":false,"textAlign":"left","textBackgroundColor":"","charSpacing":0,"minWidth":20,"styles":{} }],"height":393,"width":400}|mediaClass=Image|type=frameless|align=center|src=/images/thumb/7/71/Diagnosing_TwinSAFE_Issues_-_Advanced_Image_2.png/ia-0328ba9df3e1dd8681980d72ad4e3823-px-Diagnosing_TwinSAFE_Issues_-_Advanced_Image_2.png.png|href=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 2.png|resource=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 2.png|caption=|size=400px}} | ||
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| + | "Go live" by selecting Twinsafe->Show Online Data{{#annotatedImageLight:Fichier:Diagnosing TwinSAFE Issues - Advanced Image 3.png|0=400px|hash=3122bc1ba2a6c924bb6256c080bef9a3|jsondata={"version":"2.4.6","objects":[{"type":"image","version":"2.4.6","originX":"left","originY":"top","left":0,"top":0,"width":781,"height":459,"fill":"rgb(0,0,0)","stroke":null,"strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":0.51,"scaleY":0.51,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"crossOrigin":"","cropX":0,"cropY":0,"src":"https://stuga.dokit.app/images/3/3f/Diagnosing_TwinSAFE_Issues_-_Advanced_Image_3.png","filters":[]},{"type":"wfrect","version":"2.4.6","originX":"center","originY":"center","left":282,"top":112.33,"width":100,"height":16.21,"fill":"rgba(255,0,0,0)","stroke":"#FF0000","strokeWidth":2,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1,"scaleY":1,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"rx":0,"ry":0}],"height":235,"width":400}|mediaClass=Image|type=frameless|align=center|src=/images/thumb/3/3f/Diagnosing_TwinSAFE_Issues_-_Advanced_Image_3.png/ia-3122bc1ba2a6c924bb6256c080bef9a3-px-Diagnosing_TwinSAFE_Issues_-_Advanced_Image_3.png.png|href=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 3.png|resource=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 3.png|caption=|size=400px}} | ||
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| + | If the estop circuit is working properly, the surround will be green. If the circuit has not been initialised or there is a problem, it will be red. This picture shows a healthy estop circuit{{#annotatedImageLight:Fichier:Diagnosing TwinSAFE Issues - Advanced Image 4.png|0=400px|hash=|jsondata=|mediaClass=Image|type=frameless|align=center|src=https://stuga.dokit.app/images/9/95/Diagnosing_TwinSAFE_Issues_-_Advanced_Image_4.png|href=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 4.png|resource=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 4.png|caption=|size=400px}} | ||
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| + | The lines connecting the paths between the blocks indicate "Active" signals. A simple, useful rule of thumb is that an input labelled with an estop function (eg Isolator_C K2, Gate_C_Ch1, Saw Console_Estop_Ch1, etc) should be green to saw it is ok. EXCEPT when there is an "Inversion" on the input, signified by a circle inside the function block. | ||
| + | |||
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| + | In this this picture | ||
| + | |||
| + | * The Saw_Consol_Estop_Ch1 and Ch2 inputs are active high (green=ok) | ||
| + | * The Saw_Front_Guard_Key_Ch1 and Saw_Top_Guard_Key_Ch1 are active low (not green=ok) | ||
| + | {{#annotatedImageLight:Fichier:Diagnosing TwinSAFE Issues - Advanced Image 5.png|0=400px|hash=83881bc0bbaad2228bda248f7905ab12|jsondata={"version":"2.4.6","objects":[{"type":"image","version":"2.4.6","originX":"left","originY":"top","left":0,"top":0,"width":585,"height":457,"fill":"rgb(0,0,0)","stroke":null,"strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1,"scaleY":1,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"crossOrigin":"","cropX":0,"cropY":0,"src":"https://stuga.dokit.app/images/c/c9/Diagnosing_TwinSAFE_Issues_-_Advanced_Image_5.png","filters":[]},{"type":"wfarrow2line","version":"2.4.6","originX":"center","originY":"center","left":330,"top":187,"width":112,"height":90,"fill":"rgba(255,0,0,0)","stroke":"#FF0000","strokeWidth":4,"strokeDashArray":null,"strokeLineCap":"round","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1,"scaleY":1,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"x1":56,"x2":-56,"y1":-45,"y2":45,"x2a":-35.39869243760552,"y2a":38.70824931202547,"x2b":-45.420950170662294,"y2b":26.236106355332595},{"type":"wfarrow2circle","version":"2.4.6","originX":"center","originY":"center","left":386,"top":142,"width":16,"height":16,"fill":"#aaa","stroke":"#666","strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1,"scaleY":1,"angle":0,"flipX":false,"flipY":false,"opacity":0.5,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"radius":8,"startAngle":0,"endAngle":6.283185307179586},{"type":"wfarrow2circle","version":"2.4.6","originX":"center","originY":"center","left":274,"top":232,"width":16,"height":16,"fill":"#aaa","stroke":"#666","strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1,"scaleY":1,"angle":0,"flipX":false,"flipY":false,"opacity":0.5,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"radius":8,"startAngle":0,"endAngle":6.283185307179586},{"type":"textbox","version":"2.4.6","originX":"center","originY":"center","left":449.01,"top":135.36,"width":81.15,"height":48.82,"fill":"#FF0000","stroke":"#FF0000","strokeWidth":1,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1.37,"scaleY":1.37,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"text":"Inversion Dot","fontSize":20,"fontWeight":"normal","fontFamily":"sans-serif","fontStyle":"normal","lineHeight":1.16,"underline":false,"overline":false,"linethrough":false,"textAlign":"left","textBackgroundColor":"","charSpacing":0,"minWidth":20,"styles":{} }],"height":457,"width":585}|mediaClass=Image|type=frameless|align=center|src=/images/thumb/c/c9/Diagnosing_TwinSAFE_Issues_-_Advanced_Image_5.png/ia-83881bc0bbaad2228bda248f7905ab12-px-Diagnosing_TwinSAFE_Issues_-_Advanced_Image_5.png.png|href=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 5.png|resource=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 5.png|caption=|size=400px}} | ||
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| + | =Intermittent problems= | ||
The most difficult and frustrating problem solving comes from an intermittent problem with the TwinSAFE Estop circuit. Due to the fail-safe nature of the system, any upset or break in the EtherCAT circuit will also trip the estop circuit. Here are some tips and tricks to help narrow down this search | The most difficult and frustrating problem solving comes from an intermittent problem with the TwinSAFE Estop circuit. Due to the fail-safe nature of the system, any upset or break in the EtherCAT circuit will also trip the estop circuit. Here are some tips and tricks to help narrow down this search | ||
| − | === CRC Checking EtherCAT circuit === | + | ===CRC Checking EtherCAT circuit=== |
See [https://stuga.dokit.app/wiki/Diagnosing_EtherCAT_Issues_-_Advanced Diagnosing EtherCAT Issues] - Advanced for a guide on how to set up advanced diagnosis on the EtherCAT network to help track down intermittent breaks in the network | See [https://stuga.dokit.app/wiki/Diagnosing_EtherCAT_Issues_-_Advanced Diagnosing EtherCAT Issues] - Advanced for a guide on how to set up advanced diagnosis on the EtherCAT network to help track down intermittent breaks in the network | ||
| − | === Checking Safety Project Online View === | + | ===Checking Safety Project Online View=== |
| + | A good tool for checking "where" the break was on the safety circuit is to use the "Safety Project Online View" | ||
| + | |||
| + | With the TwinSafeGroup1 window open, Select View->Other Windows->Safety Project Online View{{#annotatedImageLight:Fichier:Diagnosing TwinSAFE Issues - Advanced Image 6.png|0=400px|hash=c3fd8f08d43c270f6c09f846c34e5b17|jsondata={"version":"2.4.6","objects":[{"type":"image","version":"2.4.6","originX":"left","originY":"top","left":0,"top":0,"width":881,"height":837,"fill":"rgb(0,0,0)","stroke":null,"strokeWidth":0,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1,"scaleY":1,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"crossOrigin":"","cropX":0,"cropY":0,"src":"https://stuga.dokit.app/images/1/15/Diagnosing_TwinSAFE_Issues_-_Advanced_Image_6.png","filters":[]},{"type":"wfrect","version":"2.4.6","originX":"center","originY":"center","left":614.14,"top":728.71,"width":212.72,"height":35.45,"fill":"rgba(255,0,0,0)","stroke":"#FF0000","strokeWidth":2,"strokeDashArray":null,"strokeLineCap":"butt","strokeDashOffset":0,"strokeLineJoin":"miter","strokeMiterLimit":4,"scaleX":1,"scaleY":1,"angle":0,"flipX":false,"flipY":false,"opacity":1,"shadow":null,"visible":true,"clipTo":null,"backgroundColor":"","fillRule":"nonzero","paintFirst":"fill","globalCompositeOperation":"source-over","transformMatrix":null,"skewX":0,"skewY":0,"rx":0,"ry":0}],"height":837,"width":881}|mediaClass=Image|type=frameless|align=center|src=/images/thumb/1/15/Diagnosing_TwinSAFE_Issues_-_Advanced_Image_6.png/ia-c3fd8f08d43c270f6c09f846c34e5b17-px-Diagnosing_TwinSAFE_Issues_-_Advanced_Image_6.png.png|href=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 6.png|resource=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 6.png|caption=|size=400px}} | ||
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| − | === Creating Sync Units ===</translate> | + | |
| + | This will open a new window at the bottom{{#annotatedImageLight:Fichier:Diagnosing TwinSAFE Issues - Advanced Image 7.png|0=400px|hash=|jsondata=|mediaClass=Image|type=frameless|align=center|src=https://stuga.dokit.app/images/d/df/Diagnosing_TwinSAFE_Issues_-_Advanced_Image_7.png|href=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 7.png|resource=./Fichier:Diagnosing TwinSAFE Issues - Advanced Image 7.png|caption=|size=400px}} | ||
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| + | The tree branches colour themselves red where there is an issue. Scrolling through these tree branches will help identify exactly where the last estop break was detected in the network. | ||
| + | |||
| + | ===Creating Sync Units=== | ||
| + | Following a discussion with Jamie Withers at Beckhoff, he recommends a "Standard code of practice" for TwinSAFE systems to put the Safety system into a [https://infosys.beckhoff.com/english.php?content=../content/1033/tc3_io_intro/1468206859.html&id= Sync Unit]. The TwinSAFE on Stuga Machines was not originally set up like this, so it is a good idea to retrospectively add this feature. It has proved incredibly successful is isolating an ethercat network problem to prevent it tripping the emergency stop circuit. It allows the engineer to trace the problem without the machine stopping. | ||
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Version du 5 octobre 2021 à 10:33
How to diagnose TwinSAFE problems
Permanent Problems
Permanent problems are issues that are permanently there until you solve them. For instance, the emergency stop circuit will not reset, but there is no indication why.
Check the EtherCAT circuit
See See Diagnosing EtherCAT Issues - Advanced to see if there is a permanent break in the etherCAT circuit, as this will also stop the emergency stop resetting
If you cannot see what is stopping estop working, you can take a look at the internals of the safety function blocks using the online view.
Firstly, get the TwinSafeGroup open
The function block screen can be zoomed in and out to show you more of it, and you can scroll round with the scroll bars
"Go live" by selecting Twinsafe->Show Online Data
If the estop circuit is working properly, the surround will be green. If the circuit has not been initialised or there is a problem, it will be red. This picture shows a healthy estop circuit
The lines connecting the paths between the blocks indicate "Active" signals. A simple, useful rule of thumb is that an input labelled with an estop function (eg Isolator_C K2, Gate_C_Ch1, Saw Console_Estop_Ch1, etc) should be green to saw it is ok. EXCEPT when there is an "Inversion" on the input, signified by a circle inside the function block.
In this this picture
- The Saw_Consol_Estop_Ch1 and Ch2 inputs are active high (green=ok)
- The Saw_Front_Guard_Key_Ch1 and Saw_Top_Guard_Key_Ch1 are active low (not green=ok)
Intermittent problems
The most difficult and frustrating problem solving comes from an intermittent problem with the TwinSAFE Estop circuit. Due to the fail-safe nature of the system, any upset or break in the EtherCAT circuit will also trip the estop circuit. Here are some tips and tricks to help narrow down this search
CRC Checking EtherCAT circuit
See Diagnosing EtherCAT Issues - Advanced for a guide on how to set up advanced diagnosis on the EtherCAT network to help track down intermittent breaks in the network
Checking Safety Project Online View
A good tool for checking "where" the break was on the safety circuit is to use the "Safety Project Online View"
With the TwinSafeGroup1 window open, Select View->Other Windows->Safety Project Online View
This will open a new window at the bottom
The tree branches colour themselves red where there is an issue. Scrolling through these tree branches will help identify exactly where the last estop break was detected in the network.
Creating Sync Units
Following a discussion with Jamie Withers at Beckhoff, he recommends a "Standard code of practice" for TwinSAFE systems to put the Safety system into a Sync Unit. The TwinSAFE on Stuga Machines was not originally set up like this, so it is a good idea to retrospectively add this feature. It has proved incredibly successful is isolating an ethercat network problem to prevent it tripping the emergency stop circuit. It allows the engineer to trace the problem without the machine stopping.
Draft
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