Add TRO identification for the Mubea seat-cover store (500573)

Works out which TROs the control system will need for drawing 500573_60_1, derived from the mechanical DXF and matched against the TRO catalog, plus the annotated figures it refers to. Co-Authored-By: Claude Opus 5 (1M context) <noreply@anthropic.com>
2026-07-30 13:13:56 +02:00
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+# Identifying the Control Units (TROs) from a Mechanical Layout
+### Mubea seat-cover store — Schönenberger drawing `500573_60_1`
+
+**Author:** Automation Engineering · **As of:** 2026-07-28 · **Source:** `500573_60_1.dxf` (23.8 MB)
+
+---
+
+## 0. For readers outside our team — what this document is
+
+Schönenberger builds the **material-flow control software** (Siemens TIA Portal / SCL) that
+runs conveyor systems. A lot of that PLC code is repetitive: the same control block appears
+once per functional point on the conveyor, differing only in its parameters. We are building
+a tool that **generates that repetitive code automatically** from the plant layout.
+
+The unit of that code is a **TRO — "Transfer Route Object"**: the control logic for **one
+hand-over point** on the conveyor. A TRO is, for example, *one* stopper, *one* switch, *one*
+storage block, or *one* driven conveyor segment. A plant is described as a set of connected
+TROs.
+
+**This document is the first step for a new plant:** we take the *mechanical* CAD drawing of
+the Mubea seat-cover store and work out **which TROs the control system will need, and why** —
+before any code is written. It is an engineering proposal, not yet a verified list (see §6).
+
+> **Key limitation, stated up front:** this DXF is a **mechanical / steel-construction
+> drawing**. It contains **no TRO numbers and no electrical signal tags** — those live in the
+> electrical documentation, not here. Every TRO below is therefore **inferred** from the
+> physical equipment we can see (drives, a switch, separators, scanners, gravity lanes) and
+> matched to our standard type catalogue in
+> [../TRO_Katalog/TRO_Katalog.md](../TRO_Katalog/TRO_Katalog.md).
+
+---
+
+## 1. The plant in plain language
+
+| | |
+|---|---|
+| **Customer / project** | Mubea — 500573 "Sitzbezügelager" (seat-cover store), Wendlingen |
+| **Conveyor system** | Schönenberger **TX200** overhead hanger conveyor |
+| **What moves** | **Bügelträger** — hanger carriers that carry seat covers (*Sitzpolster* = cushion, *Lehne* = backrest) |
+| **What the plant does** | Empty hanger carriers are **loaded** with covers, **circulate** on a powered track, are **stored** when empty in a large **gravity buffer**, pass a **quality-control** point, and can take an **express** route |
+
+**Indicative material flow** (components are certain; exact routing is to be confirmed):
+
+```mermaid
+flowchart LR
+    classDef store fill:#d4f0d4,stroke:#338833,color:#111
+    classDef swi   fill:#ffe4a0,stroke:#cc8800,color:#111
+    classDef sep   fill:#d4e8ff,stroke:#3388cc,color:#111
+    classDef vario fill:#e8d4f0,stroke:#883388,color:#111
+
+    AUF["Aufgabestation<br/>load covers onto hangers"]:::sep
+    V["Powered track<br/>(TX200 friction drive)"]:::vario
+    W["Weiche W.12000.1<br/>diverter"]:::swi
+    QC["Qualitätskontrolle<br/>inspection stop"]:::sep
+    EXP["Express route"]:::sep
+    STORE["PinStore — gravity buffer<br/>~20 gravity lines · 1 separator per line"]:::store
+
+    AUF --> V --> W
+    W -->|standard| QC
+    W -->|express| EXP
+    QC --> STORE
+    STORE -->|release empties| AUF
+```
+
+![The DXF: conveyor plan (centre), sections (left), steel platform (right)](img/drawing_full.png)
+
+---
+
+## 2. How we read the drawing (method & evidence)
+
+Parsed with the `ezdxf` library. A full-text scan confirmed there are **no `TRO…` labels and
+no `BG/MA/MB/BX…` electrical tags**. Identification therefore relies on four things a
+mechanical drawing *does* contain:
+
+1. **Named component blocks** — the mechanical part library (`S-SP` separator, `SCAN`, …).
+2. **Equipment serials** carried as block attributes — `M.12000` (drive motor),
+   `W.12000.1` (switch), motor spec `TX200FD · WF20 · 0.37 kW · pitch 127`.
+3. **Layer names** (German construction codes) — decisive for the gravity finding:
+   - `ABH-GEF-DRT` — *Abhängung **Gefälle** DRT* → **gravity (sloped) track** ✔ the store lines
+   - `TX200FD` — *Friction Drive* → the **powered** circulation track
+   - `5SEP-SP` — *Separator/Sperre*, `ZZSCANNER` — scanners, `3-BO-90/180` — curves
+4. **Station labels** (text) — `Aufgabestation`, `Qualitätskontrolle`, `Express`,
+   `leere Bügelträger Rückführung`.
+
+### Equipment actually present (main plan, duplicate detail removed)
+
+| Element (block / tag) | What it is | Count | Powered? |
+|---|---|---:|---|
+| `M.12000` friction drives (`TX200-41019-D`) | motorised track segments | ~7 | powered (`TX200FD`) |
+| `W.12000.1` switch (`TX200-41302-D`) | one diverter / Weiche | 1 | powered |
+| `S-SP` separators (`5SEP-SP`) | one stopper per storage line | ~22 | on **gravity** lines |
+| storage lanes (`ABH-GEF-DRT`) | gravity accumulation lines | ~20 | **gravity** |
+| `SCAN` (`ZZSCANNER`) | barcode read points | 8 | — |
+| `3-BO-90/180`, curves | passive track bends (not TROs) | many | — |
+
+---
+
+## 3. What changed vs. the first draft (corrections)
+
+Three domain corrections from review, now applied:
+
+1. **The big multi-lane block is the PinStore**, not an "empty-carrier buffer". It is the
+   single storage block that holds **all** the lines. → type **`PinStore_Auto`**.
+2. **The storage lines are gravity lines** (layer `ABH-GEF-DRT`, *Gefälle*), not driven —
+   carriers roll down each lane and are held by the line separator. This is now the defining
+   evidence for the PinStore.
+3. **There is no `Vario_workStation`.** The `Aufgabestation` and `Qualitätskontrolle` are
+   stop points on the track, not driven manual-station modules. They are modelled as simple
+   separators (`1Sep`).
+
+---
+
+## 4. Identified TROs
+
+Types refer to [../TRO_Katalog/TRO_Katalog.md](../TRO_Katalog/TRO_Katalog.md). IDs are
+provisional — the plant has no control numbering yet.
+
+| TRO (provisional) | Type | Why we chose this type | Confidence |
+|---|---|---|---|
+| **Store** — *leere Bügelträger Rückführung* | **`PinStore_Auto`** | One storage block holding **all ~20 lines**; each line is a **gravity** lane (`ABH-GEF-DRT`) with its own `S-SP` separator that releases carriers one at a time — the defining pattern of a pin/line store | **Very high** |
+| **Weiche `W.12000.1`** | **`1Sep1Swi`** | The single diverter in the plant (serial `W.12000.1`): one entry, two exits (standard vs. Express) | **High** |
+| **Transport segments** ×~5–7 | **`Vario`** | Each `M.12000` friction-drive motor (`TX200FD`, 0.37 kW) powers one section of the circulation track — a driven conveyor segment | High (type) / Medium (count) |
+| **Read stop(s)** at scanners | **`1Sep_SSCC`** / `1Sep`+scanner | Where a `SCAN` sits at a stopper, the carrier is halted and its barcode read before release | Medium |
+| **Aufgabestation** (loading) | **`1Sep`** | A stop where an operator loads covers, then releases the carrier — a plain separator, **not** a driven work-station module | Medium |
+| **Qualitätskontrolle** (inspection) | **`1Sep`** | A stop point for manual inspection on the powered track | Medium |
+| **Express branch** | **`1Sep`** | The stopper feeding the switch's express exit | Low–Medium |
+
+**PinStore — the heart of the plant** (gravity lines, one `S-SP` separator each):
+
+![PinStore gravity buffer — separators orange, scanners green, switch blue, drives red](img/buffer_zone.png)
+
+**Aufgabestation / loading zone** (drives + scanner feeding the store's track):
+
+![Aufgabestation zone](img/aufgabe_zone.png)
+
+**Annotated overview** of the whole plan:
+
+![Annotated overview](img/overview_annotated.png)
+
+---
+
+## 5. Glossary (German ↔ meaning)
+
+| Term | Meaning |
+|---|---|
+| **TRO** | *Transfer Route Object* — our control block for one hand-over point |
+| **Bügelträger** | hanger carrier (holds the seat covers) |
+| **Aufgabestation** | loading / infeed station |
+| **Qualitätskontrolle** | quality control |
+| **Weiche** | switch / diverter (two-way) |
+| **Vereinzeler / Sperre** (`S-SP`) | separator / stopper — releases one carrier at a time |
+| **Gefälle** (`ABH-GEF`) | gravity slope — the lines the carriers roll down |
+| **PinStore** | multi-line gravity accumulation store |
+| **Vario** | driven (friction/chain) conveyor segment |
+| **TX200** | Schönenberger overhead-conveyor product line (`FD` = friction drive) |
+
+---
+
+## 6. Assumptions & next steps
+
+- **Certain:** the plant is built around **one gravity PinStore** and **one switch**, served
+  by a **friction-driven** TX200 loop with barcode scanners. The *component types* are solid.
+- **Approximate:** the **number and boundaries of the `Vario` segments** and the **exact
+  routing** are read from geometry and need confirmation.
+- **A detail sub-region is drawn twice** (shifted ~55.7 m in X, same serials `M.12000` /
+  `W.12000.1`) — counted once here.
+- **To turn this into a verified TRO list** we need the same inputs as a normal project:
+  the **electrical I/O list** (for the sensor/motor tags per unit) and, once it exists, the
+  **`FB_Main`** call sites (for TRO numbering, direction logic and jam areas) — the workflow
+  described in [../HundM/EA-Listen-Analyse.md](../HundM/EA-Listen-Analyse.md) and
+  [../HundM/Json_Layout-Konzept.md](../HundM/Json_Layout-Konzept.md).
+
+*Figures generated from `500573_60_1.dxf` with `ezdxf`; markers overlaid on the block-insert
+coordinates.*