sps_skel/doc/500573_Mubea/TRO_Identifikation_500573.md

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)

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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.

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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):

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

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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	—

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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).

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4. Identified TROs

Types refer to ../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):

Aufgabestation / loading zone (drives + scanner feeding the store's track):

Annotated overview of the whole plan:

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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)

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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 and ../HundM/Json_Layout-Konzept.md.

Figures generated from 500573_60_1.dxf with ezdxf; markers overlaid on the block-insert coordinates.