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JSON Layout-Konfiguration fuer HundM_Fortna SCL-Code-Generierung

Kontext

Die 5 SPS-Konfigurationen (UH01-UH05) enthalten tausende Zeilen repetitiven SCL-Code in FB_Main, FB_CallSensors, FC_Direction und FC_Call_Jams. Dieser Code folgt festen Mustern pro Element-Typ und unterscheidet sich nur in den konkreten Parametern (Adressen, Sensor-IDs, TRO-Nummern, Timing-Werte). Eine JSON-Konfigurationsdatei koennte als Single Source of Truth dienen, aus der der gesamte topologie-spezifische SCL-Code generiert wird.

Identifizierte Element-Typen (aus FB_Main UH01)

Typ FB-Typ Anzahl UH01 Kennzeichen
Conveyor/Carousel FB_Conveyor 13 Motor, Grid-Sensor, Schaltschrank
TRO 1Sep FB_ILS_MTRO_1Sep ~15 1 Separator, Entry/Exit Jam
TRO 1Sep + Scanner FB_ILS_MTRO_1Sep 5 + Cognex Barcode-Reader
TRO 1Sep1Swi FB_ILS_MTRO_1Sep1Swi 4 + Switch mit Direction-Logik
TRO 1Sep SSCC FB_ILS_MTRO_1Sep_SSCC 2 + SSCC-Scanner + DReqM Telegramm
TRO Vario FB_ILS_MTRO_Vario 9 Ketten-/Variofuerderer
EmptyCarrBuffer FB_EmptyCarrBuffer 2 Mehrzeiliger Puffer + Weichen
LoadingBoom FB_LoadingBoom_INBOUND 2 Komplex: Boom, Fuss, Stopper, Tilt, Distance
Sensor FB_SensorInput ~200 Pro physischem Sensor

Vorschlag fuer eine standardisierte TRO-Liste

Uebersicht aller TROs nach Steuerung

Insgesamt wurden 237 TROs ueber alle 5 Steuerungen identifiziert. Die TRO-IDs folgen dem Schema TRO<UH-Nr><lfd> (z.B. TRO100-TRO134 fuer UH01).

Steuerung TRO-Bereich Anzahl TROs Schwerpunkt
UH01 TRO100-TRO134 21 Inbound, Loading Booms, SSCC-Scanner, Empty Carrier Buffer
UH02 TRO200-TRO275 76 3x PinStore-Bloecke (automatisiertes Lager)
UH03 TRO301-TRO386 84 3x PinStore-Bloecke (2.1, 2.2, 2.3) + F2H
UH04 TRO402-TRO424 24 3x Work Stations (manuelle Arbeitsplaetze)
UH05 TRO500-TRO531 32 Laengenmessung + Verteilsystem

FB-Typ-Verteilung ueber alle Steuerungen

FB-Typ Beschreibung UH01 UH02 UH03 UH04 UH05 Gesamt
FB_ILS_MTRO_1Sep Standard-Separator ~15 ~20 ~25 ~8 ~10 ~78
FB_ILS_MTRO_Vario Kettenfoerderer (variabel) 9 ~15 ~18 4 ~12 ~58
FB_ILS_MTRO_1Sep1Swi Separator + 1 Weiche 4 ~8 ~12 3 5 ~32
FB_ILS_MTRO_1Sep2Swi Separator + 2 Weichen 0 ~5 ~6 0 0 ~11
FB_ILS_MTRO_PinStore_Auto Automatisches Pin-Lager 0 ~20 ~18 0 0 ~38
FB_ILS_MTRO_1Sep_SSCC SSCC-Barcode-Scanner 2 0 0 0 0 2
FB_ILS_MTRO_Vario_workStation Manueller Arbeitsplatz 0 0 0 3 0 3
FB_EmptyCarrBuffer Leertablar-Puffer 2 0 0 0 0 2

Detaillierte TRO-Liste UH01

TRO FB-Typ Scanner Switch Prio Besonderheit
TRO100 1Sep - - releaseOk Eingang Kreisel
TRO101_IN 1Sep - - releaseOk Eingang Empty Buffer rechts
TRO101 EmptyCarrBuffer - - Manager 5-Zeilen Leertablar-Puffer rechts
TRO102_IN 1Sep - - releaseOk Eingang Empty Buffer links
TRO102 EmptyCarrBuffer - - Manager 5-Zeilen Leertablar-Puffer links
TRO103 1Sep - - releaseOk Zufahrt Loading Boom 1
TRO104 1Sep BX1103 - releaseOk Stopper vor Boom 1 + Barcode
TRO105 1Sep_SSCC BX1104 + BX1107 - releaseOk SSCC-Scanner Boom 1 + WCS DReqM
TRO106 1Sep - - Manager Abfahrt Boom 1
TRO107 1Sep1Swi - cSwi107.1 Dir2 Manager Weiche Boom 1 (LS / Clearing)
TRO108 1Sep - - releaseOk Zufahrt Loading Boom 2
TRO109 1Sep BX1105 - releaseOk Stopper vor Boom 2 + Barcode
TRO110 1Sep_SSCC BX1106 + BX1108 - releaseOk SSCC-Scanner Boom 2 + WCS DReqM
TRO111 1Sep - - Manager Abfahrt Boom 2
TRO112 1Sep1Swi - cSwi112.1 Dir2 Manager Weiche Boom 2 (LS / Clearing)
TRO113 1Sep BX1101 - releaseOk RFID + Barcode vor Ausfahrt
TRO114 1Sep1Swi - cSwi114.1 - Weiche Inbound Out / Clearing
TRO115 Vario - - releaseOk Loaded to Storage (Kette)
TRO116 1Sep - - releaseOk Separator vor Clearing
TRO117 1Sep BX1100 - Manager Clearing Station + Barcode
TRO120 Vario - - releaseOk Highway Vario
TRO121 Vario - - releaseOk Highway Vario
TRO122 1Sep - - releaseOk Highway Separator
TRO123 Vario - - releaseOk Highway Vario
TRO124 1Sep1Swi - cSwi124.1 Manager Weiche Highway (Storage / Inbound)
TRO125 1Sep - - Manager Highway Separator
TRO126 Vario - - releaseOk Empty to Storage (Kette)
TRO127 Vario - - releaseOk Empty to Inbound (Kette)
TRO128 Vario - - releaseOk Loaded to AMR (Kette)
TRO129 1Sep - - Manager Highway Separator
TRO130 1Sep - - Manager Highway Separator
TRO131 Vario - - releaseOk Highway Vario
TRO132 1Sep - - releaseOk Highway Separator
TRO133 Vario - - releaseOk Highway Vario
TRO134 Vario - - releaseOk Highway Vario

Spezial-Elemente je Steuerung

Feature UH01 UH02 UH03 UH04 UH05
SSCC-Scanner TRO105, TRO110 - - - -
Cognex Barcode BX1100-BX1108 - - BX4103 BX5101
PinStore (autom. Lager) - 3 Bloecke 3 Bloecke (2.1-2.3) - -
Work Station (manuell) - - - TRO421-423 -
Laengenmessung - - - - TRO500
Empty Carrier Buffer TRO101, TRO102 - - - -
Loading Boom Boom1, Boom2 - - - -
Borner (Einschleusung) TRO101, TRO102 TRO200, 240, 270, 272 - - TRO500, 502
F2H (Floor-to-Hub) - - TRO308, 383, 386 - -

Namenskonvention fuer standardisierte JSON-Konfiguration

Um eine einheitliche JSON pro Steuerung zu erzeugen, wird folgendes Schema empfohlen:

TRO-ID:          TRO<UH-Nr * 100 + lfd>    z.B. TRO115, TRO207, TRO315
Separator-Nr:    cSep<TRO-ID>.1             z.B. cSep115.1
Switch-Nr:       cSwi<TRO-ID>.1             z.B. cSwi107.1
MainTroNo:       cMainTro<TRO-ID>           z.B. cMainTro115
JamArea-DB:      DB_JamArea<4-stellig>      z.B. DB_JamArea0107
Scanner-ID:      cScannerBX<4-stellig>      z.B. cScannerBX1104
HMI-Pfad:        DB_Interface_HMI.stTRO.TRO<ID>

Vorgeschlagene JSON-Struktur

1. Projekt-Header & SPS-Konfiguration

{
  "$schema": "hmf-layout-v1.schema.json",
  "version": "1.0",
  "project": "HundM_Fortna",

  "plc": {
    "id": "UH01",
    "configName": "=A01+UH01-KF00",
    "plcId": "cPLCID",
    "connectionIdWCSBL": 10
  },

  "controlUnits": [
    {
      "id": "OF1",
      "safetySignal": "DB_InterfaceSafety.stFromSafety.EStopMainOF1.Q",
      "mainContactors": [
        "DB_InterfaceSafety.stFromSafety.stMainContactorsUH01.Q",
        "DB_InterfaceSafety.stFromSafety.stMainContactorsUC0110.Q",
        "DB_InterfaceSafety.stFromSafety.stMainContactorsUC0111.Q"
      ],
      "machineState": "DB_MachineGlobal.stStateMainOF1"
    },
    {
      "id": "OF2",
      "safetySignal": "DB_InterfaceSafety.stFromSafety.EStopMainOF2.Q",
      "mainContactors": [
        "DB_InterfaceSafety.stFromSafety.stMainContactorsUC011.Q"
      ],
      "machineState": "DB_MachineGlobal.stStateMainOF2"
    }
  ]
}

2. Sensoren (erzeugt FB_CallSensors)

"sensors": [
  {
    "id": "BG0280",
    "constant": "cInBG0280",
    "hwInput": "BG0280",
    "controlUnit": "OF1",
    "comment": "TRO104 Sep Sensor"
  },
  {
    "id": "BG0282",
    "constant": "cInBG0282",
    "hwInput": "BG0282",
    "controlUnit": "OF1",
    "comment": "LoadingBoom1 Stopper1"
  }
]

3. Conveyors / Carousels (erzeugt REGION Conveyor in FB_Main)

Standard-Conveyor (Carousel mit Grid-Sensor)

"conveyors": [
  {
    "id": "Carousel0101",
    "instanceName": "fbCarousel0101",
    "comment": "Eingangskreisel",
    "controlUnit": "OF1",
    "settings": {
      "energySafeTime": "cTimeEnergySafe",
      "gridActive": true,
      "motorProtectName": "FC0060",
      "gridSenName": "BG3347"
    },
    "io": {
      "enabled": "cTodoTRUE",
      "gridSensor": "cInBG3347",
      "gridQuit": ["SF0031", "SF0002"],
      "motorProtection": "FC0060",
      "powerContactor": "MA0060",
      "hmiPath": "DB_Interface_HMI.stConveyors.stCarousel.stCar0101"
    },
    "requestRunSources": [
      { "type": "startupCounter", "value": 100 },
      { "type": "restart" },
      { "type": "troCarouselReq", "tro": "TRO100" },
      { "type": "troCarouselReq", "tro": "TRO101_IN" },
      { "type": "troCarouselReq", "tro": "TRO102_IN" }
    ]
  }
]

Buersten-Conveyor (Subtype brush)

{
  "id": "Conveyor4103_B",
  "instanceName": "fbConveyor4103_B",
  "comment": "Buersten Highway Loaded to Storage",
  "controlUnit": "OF2",
  "subtype": "brush",
  "settings": {
    "energySafeTime": "T#90s",
    "gridActive": false,
    "motorProtectName": "FC0152"
  },
  "io": {
    "motorProtection": "FC0152",
    "powerContactor": "MA0152",
    "hmiPath": "DB_Interface_HMI.stConveyors.stCarousel.stCar4103_B"
  },
  "brushConfig": {
    "triggerSensor": "cInBG3140",
    "jamSensor": "cInBG3143",
    "fullSensor": "cInBG3142",
    "taktTime": "T#1s"
  }
}

4. TROs (Transfer Route Objects)

TRO 1Sep — Standard-Separator

"tros": [
  {
    "id": "TRO100",
    "type": "1Sep",
    "fbType": "FB_ILS_MTRO_1Sep",
    "mainTroNo": "cMainTro100",
    "controlUnit": "OF1",
    "comment": "Eingang Kreisel",
    "separator": {
      "no": "cSep100.1",
      "delayToNextItem": "TimeForSepWaiting_Short",
      "trailingTime": "T#600ms",
      "handlingTime": "T#200ms",
      "jamTime": "TimeForSepJam",
      "senFree": "T#1500ms",
      "senWait": "T#4000ms",
      "plugged": {
        "jam": true,
        "part": false,
        "scanner": false
      },
      "sensorInSep": "cInBG3242"
    },
    "sensorJam2": "cInBG3243",
    "priority": { "releaseOk": true },
    "call": {
      "carouselRun": "fbCarousel0101.xOutConveyorFullSpeed",
      "release": "DB_TRO_TEST.TRO100"
    },
    "jamAreas": {
      "entry": "DB_JamArea0100.stJam0100_1",
      "exit": "DB_JamArea0101.stJam0101_1"
    },
    "outputs": {
      "stopper1": "MB3242"
    },
    "hmi": "DB_Interface_HMI.stTRO.TRO100"
  }
]

TRO 1Sep1Swi — Separator + Switch mit Direction-Logik

{
  "id": "TRO107",
  "type": "1Sep1Swi",
  "fbType": "FB_ILS_MTRO_1Sep1Swi",
  "mainTroNo": "cMainTro107",
  "controlUnit": "OF1",
  "comment": "Switch Boom 1",
  "separator": {
    "no": "cSep107.1",
    "delayToNextItem": "TimeForSepWaiting_Short",
    "trailingTime": "T#100ms",
    "handlingTime": "T#50ms",
    "jamTime": "TimeForSepJam",
    "plugged": { "jam": true, "part": false, "scanner": false },
    "sensorInSep": "cInBG3306"
  },
  "sensorJam2": "cInBG3305",
  "sensorJam3": "cInBG3330",
  "switch": {
    "no": "cSwi107.1",
    "pluggedExSen3": false,
    "pluggedExSen4": false,
    "nTo1Destinations": 3
  },
  "settings": {
    "prioDir2": true
  },
  "priority": {
    "managerDir2In": "DB_Prozessdaten.stPriorityManager.udt_TRO107.TroIn",
    "managerDir2Out": "DB_Prozessdaten.stPriorityManager.udt_TRO107.TroOut"
  },
  "call": {
    "carouselRun1": "fbCarousel0102.xOutConveyorFullSpeed",
    "release": "true"
  },
  "jamAreas": {
    "entry": "DB_JamArea0102.stJam0102_1",
    "exit2": "DB_JamArea0103.stJam0103_1",
    "exit3": "DB_JamArea0102.stJam0102_2"
  },
  "outputs": {
    "stopper1": "MB3306",
    "sw1ExTo3": "MB3304"
  },
  "hmi": "DB_Interface_HMI.stTRO.TRO107",
  "direction": {
    "switchNo": "cSwi107.1",
    "carrierSource": "DB_JamArea0102.stJam0102_1.arCarrier[1]"
  }
}

TRO Vario — Kettenfoerderer

{
  "id": "TRO115",
  "type": "Vario",
  "fbType": "FB_ILS_MTRO_Vario",
  "mainTroNo": "cMainTro115",
  "controlUnit": "OF1",
  "comment": "Loaded To Storage Vario",
  "separator": {
    "no": "cSep115.1",
    "delayToNextItem": "TimeForSepWaiting_Short",
    "trailingTime": "T#800ms",
    "handlingTime": "T#300ms",
    "jamTime": "TimeForSepJam",
    "senFree": "T#2000ms",
    "senWait": "T#5000ms",
    "plugged": { "jam": false, "part": false, "scanner": false },
    "sensorInSep": "cInBG3025"
  },
  "vario": {
    "continousEmptying": false,
    "waitForJog": "T#300ms",
    "convEmpty": "T#45000ms",
    "countCarrier": 1,
    "waitForStop": "T#3s",
    "carrierInPosDelay": "T#1200ms",
    "carrierInPosEdgeDelay": "T#100ms",
    "rasterHigh": "T#5s",
    "rasterLow": "T#5s",
    "jamSenDelayActive": true,
    "jamSenDelay": "T#2s",
    "sensors": {
      "carrInPos": "cInBG3026",
      "finger": "cInBG3027",
      "lastPos": "cInBG3000",
      "jam": "cInBG3001"
    }
  },
  "settings": { "isBorner": true },
  "priority": { "releaseOk": true },
  "call": {
    "motorProtection": "FC0145",
    "automatic": "#t_Automatik_OF1 AND SF0120",
    "errorQuit": "SF0002",
    "release": "DB_TRO_TEST.TRO115"
  },
  "jamAreas": {
    "entry": "DB_JamArea4104.stJam4104_1",
    "finger": "DB_JamArea4103.stJam4103_1"
  },
  "outputs": {
    "stopper": "MB3025",
    "varioMotor": "MA0145"
  },
  "hmi": "DB_Interface_HMI.stTRO.TRO115"
}

TRO 1Sep_SSCC — SSCC-Scanner + WCS-Telegramm

{
  "id": "TRO105",
  "type": "1Sep_SSCC",
  "fbType": "FB_ILS_MTRO_1Sep_SSCC",
  "mainTroNo": "cMainTro105",
  "controlUnit": "OF1",
  "comment": "SSCC Scanner Boom 1",
  "separator": {
    "no": "cSep105.1",
    "delayToNextItem": "TimeForSepWaiting_Short",
    "trailingTime": "T#600ms",
    "handlingTime": "T#200ms",
    "jamTime": "TimeForSepJam",
    "senFree": "T#1500ms",
    "senWait": "T#4000ms",
    "plugged": { "jam": true, "part": false, "scanner": true },
    "sensorInSep": "cInBG3280"
  },
  "sensorJam2": "cInBG3281",
  "scanner": {
    "id": "cScannerBX1104",
    "prefix": "bx1104",
    "hwResults": "BX1104~Ergebnisse_-_64_Bytes_1",
    "checkASCII": true,
    "timeout": "T#3000ms"
  },
  "ssccScanner": {
    "prefix": "bx1107",
    "hwResults": "BX1107~Ergebnisse_-_64_Bytes_1",
    "checkASCII": true,
    "timeout": "T#3s",
    "sensorEndMeasurement": "cInBG3281"
  },
  "priority": { "releaseOk": true },
  "call": {
    "carouselRun": "true",
    "release": "FB_CommunicationWCSBL_DB.fbTeleHandler.xOutConnectionActive OR IBN.xFahrenOhneTcpPartner"
  },
  "jamAreas": {
    "entry": "DB_JamArea0104.stJam0104_3",
    "exit": "DB_JamArea0106.stJam0106_2"
  },
  "outputs": { "stopper1": "MB3280" },
  "hmi": "DB_Interface_HMI.stTRO.TRO105",
  "correction": {
    "station": 0,
    "carrierExpect": "DB_JamArea0104.stJam0104_3.arCarrier[1]"
  },
  "wcsTelegram": {
    "type": "DReqM",
    "decisionPoint": "cDP_DOCK_01",
    "dockDoor": "1",
    "ssccReq": true,
    "lengthReq": false,
    "dockDoorReq": true
  }
}

5. Loading Booms

"loadingBooms": [
  {
    "id": "LoadingBoom1",
    "instanceName": "fbLoadingBoom1",
    "controlUnit": "OF1",
    "comment": "Ladeschleife 1",
    "relatedTro": "TRO104",
    "controls": {
      "btnReleaseMT1": "SF0305",
      "switchLoadingPos2": "SF0306",
      "btnBack": null,
      "btnForth": null,
      "btnReleaseMT2": "SF0332",
      "switchFootUp": null,
      "switchFootDown": null,
      "switchLightOnOff": "SF0041",
      "btnBoomActive": "SF0044",
      "btnReset": ["SF0043", "SF0002", "IBN.xQuit"],
      "switchFootManual": "SF0025"
    },
    "boom": {
      "motorProtection": ["FC0070", "FC0072"],
      "limitForth": "cInBG3343",
      "limitForthEmergency": "SF0051",
      "limitBack": "cInBG3344",
      "limitBackEmergency": "SF0050",
      "bumperOk": true
    },
    "foot": {
      "motorProtection": "FC0321",
      "limitUp": "SF0322",
      "limitDown": "SF0323"
    },
    "timings": {
      "boomInput": "T#5s",
      "wheelInput": "T#5s",
      "senWaitStopper1": "T#100ms",
      "waitAfterReleaseStopper1": "T#1200ms",
      "waitBeforeSwitchStopper2": "T#4000ms",
      "trailingStopper2": "T#150ms"
    },
    "tilt": {
      "analogInput": "wTiltSensorLS1",
      "hmiBasePath": "DB_Interface_HMI.stLoadingBoom.stDataBoom1"
    },
    "distance": {
      "analogInput": "wDistanceSensorLS1",
      "startSlow": 2510,
      "startFast": 2520,
      "hmiBasePath": "DB_Interface_HMI.stLoadingBoom.stDataBoom1"
    },
    "callSensors": {
      "sen2mThreshold": "cInBG0287",
      "senJamEntr": "cInBG0286",
      "senJamExit1": "cInBG0285",
      "senJamExit2": "cInBG3276",
      "senStopper1": "cInBG0282",
      "senStopper2": "cInBG0283"
    },
    "jamAreas": {
      "stopper": "DB_JamArea0104.stJam0104_2",
      "exit": "DB_JamArea0104.stJam0104_3"
    },
    "outputs": {
      "light": "QA0012",
      "boomActive": "PF0044",
      "ledMovement": "PF0287",
      "stopper1Clamp": "MB0282",
      "stopper1Finger": "MB0284",
      "stopper2": "MB0283",
      "boomForth1": "QA0071",
      "boomForth2": "QA0073",
      "boomBack1": "MA0070",
      "boomBack2": "MA0072",
      "footUp": "DQ0322",
      "footDown": "DQ0323",
      "footSpeed1": "DQ0324"
    },
    "hmi": "DB_Interface_HMI.stLoadingBoom.stDataBoom1"
  }
]

6. Empty Carrier Buffers (mehrzeiliger Puffer)

"emptyCarrBuffers": [
  {
    "id": "TRO101",
    "instanceName": "TRO101",
    "mainTroNo": "cMainTro101",
    "controlUnit": "OF1",
    "comment": "Empty Buffer rechts",
    "numberOfLines": 5,
    "storageDb": "DB_JamBuffer101",
    "inTro": {
      "id": "TRO101_IN",
      "separator": {
        "no": 999,
        "delayToNextItem": "TimeForSepWaiting_Short",
        "trailingTime": "T#100ms",
        "handlingTime": "T#50ms",
        "jamTime": "TimeForSepJam",
        "sensorInSep": "cInBG3246"
      },
      "isBorner": true,
      "bornerDest": "cDestInboundLS",
      "carouselRun": "fbCarousel0101.xOutConveyorFullSpeed",
      "jamEntry": "DB_JamArea0101.stJam0101_1",
      "stopper": "MB3246",
      "hmi": "DB_Interface_HMI.stTRO.TRO101_In"
    },
    "separatorLines": [
      { "line": 1, "jamLength": 5,  "sensor": "cInBG3320", "handlingTime": "T#200ms", "trailingTime": "T#500ms", "senFree": "T#1500ms", "senWait": "T#3000ms" },
      { "line": 2, "jamLength": 7,  "sensor": "cInBG3321", "handlingTime": "T#200ms", "trailingTime": "T#500ms", "senFree": "T#1500ms", "senWait": "T#3000ms" },
      { "line": 3, "jamLength": 10, "sensor": "cInBG3322", "handlingTime": "T#200ms", "trailingTime": "T#500ms", "senFree": "T#1500ms", "senWait": "T#3000ms" },
      { "line": 4, "jamLength": 10, "sensor": "cInBG3323", "handlingTime": "T#200ms", "trailingTime": "T#500ms", "senFree": "T#1500ms", "senWait": "T#3000ms" },
      { "line": 5, "jamLength": 10, "sensor": "cInBG3324", "handlingTime": "T#200ms", "trailingTime": "T#500ms", "senFree": "T#1500ms", "senWait": "T#3000ms" }
    ],
    "jamSensors": ["cInBG3250", "cInBG3251", "cInBG3252", "cInBG3253", "cInBG3254"],
    "switchLineOutputs": ["MB3250", "MB3251", "MB3252", "MB3253", "MB3254"],
    "separatorStoreOutputs": ["MB3320", "MB3321", "MB3322", "MB3323", "MB3324"],
    "exitJam": "DB_JamArea0102.stJam0102_2",
    "exitSensor": "cInBG3330",
    "priority": {
      "managerIn": "DB_Prozessdaten.stPriorityManager.udt_TRO101.TroIn",
      "managerOut": "DB_Prozessdaten.stPriorityManager.udt_TRO101.TroOut"
    },
    "hmi": "DB_Interface_HMI.stTRO.TRO101"
  }
]

7. Routing / FC_Direction (erzeugt CASE-Statement)

"routing": {
  "switches": [
    {
      "switchNo": "cSwi107.1",
      "comment": "Switch 107.1 Boom 1",
      "rules": [
        { "destination": "cDestInboundLS", "direction": 1, "comment": "LINKS - zu Ladeschleife" },
        { "destinations": ["cDestClearing", "cDestInboundOut", "cDestInboundLS_Extra"], "direction": 2, "comment": "RECHTS - Clearing/Inbound verlassen" }
      ],
      "default": 2
    },
    {
      "switchNo": "cSwi112.1",
      "comment": "Switch 112.1 Boom 2",
      "rules": [
        { "destinations": ["cDestInboundLS", "cDestInboundLS_Extra"], "direction": 1, "comment": "LINKS - zu Ladeschleife" },
        { "destinations": ["cDestClearing", "cDestInboundOut"], "direction": 2, "comment": "RECHTS - Clearing/Inbound verlassen" }
      ],
      "default": 2
    },
    {
      "switchNo": "cSwi114.1",
      "comment": "Switch 114.1",
      "rules": [
        { "destination": "cDestInboundOut", "direction": 1, "comment": "LINKS - Inbound verlassen" },
        { "destination": "cDestClearing", "direction": 2, "comment": "RECHTS - Clearing-Station" }
      ],
      "default": 0
    },
    {
      "switchNo": "cSwi124.1",
      "comment": "Switch 124.1",
      "rules": [
        { "destination": "cDestHighwayStorage", "direction": 1, "comment": "LINKS - zum Storage" },
        { "destination": 0, "direction": 2, "comment": "RECHTS - zum Inbound (Standard)" }
      ],
      "default": 2
    }
  ]
}

8. Jam Areas

"jamAreas": [
  {
    "id": "JamArea0100",
    "db": "DB_JamArea0100",
    "slots": [
      { "name": "stJam0100_1", "capacity": 5 }
    ]
  },
  {
    "id": "JamArea0101",
    "db": "DB_JamArea0101",
    "slots": [
      { "name": "stJam0101_1", "capacity": 5 },
      { "name": "stJam0101_2", "capacity": 5 }
    ]
  },
  {
    "id": "JamArea0102",
    "db": "DB_JamArea0102",
    "slots": [
      { "name": "stJam0102_1", "capacity": 5 },
      { "name": "stJam0102_2", "capacity": 5 },
      { "name": "stJam0102_3", "capacity": 5 },
      { "name": "stJam0102_4", "capacity": 5 },
      { "name": "stJam0102_5", "capacity": 5 },
      { "name": "stJam0102_6", "capacity": 5 }
    ]
  }
]

9. Scanners (Cognex Barcode-Reader)

"scanners": [
  {
    "id": "BX1100",
    "constant": "cScannerBX1100",
    "prefix": "bx1100",
    "hwResults": "BX1100~Ergebnisse_-_64_Bytes_1",
    "usedByTro": "TRO117"
  },
  {
    "id": "BX1101",
    "constant": "cScannerBX1101",
    "prefix": "bx1101",
    "hwResults": "BX1101~Ergebnisse_-_64_Bytes_1",
    "usedByTro": "TRO113"
  },
  {
    "id": "BX1103",
    "constant": "cScannerBX1103",
    "prefix": "bx1103",
    "hwResults": "BX1103~Ergebnisse_-_64_Bytes_1",
    "usedByTro": "TRO104"
  },
  {
    "id": "BX1104",
    "constant": "cScannerBX1104",
    "prefix": "bx1104",
    "hwResults": "BX1104~Ergebnisse_-_64_Bytes_1",
    "usedByTro": "TRO105"
  },
  {
    "id": "BX1105",
    "constant": "cScannerBX1105",
    "prefix": "bx1105",
    "hwResults": "BX1105~Ergebnisse_-_64_Bytes_1",
    "usedByTro": "TRO109"
  },
  {
    "id": "BX1106",
    "constant": "cScannerBX1106",
    "prefix": "bx1106",
    "hwResults": "BX1106~Ergebnisse_-_64_Bytes_1",
    "usedByTro": "TRO110"
  },
  {
    "id": "BX1107",
    "constant": "cScannerBX1107",
    "prefix": "bx1107",
    "hwResults": "BX1107~Ergebnisse_-_64_Bytes_1",
    "comment": "SSCC Scanner Boom 1",
    "usedByTro": "TRO105"
  },
  {
    "id": "BX1108",
    "constant": "cScannerBX1108",
    "prefix": "bx1108",
    "hwResults": "BX1108~Ergebnisse_-_64_Bytes_1",
    "comment": "SSCC Scanner Boom 2",
    "usedByTro": "TRO110"
  }
]

10. Sonderlogik — Hybrid-Ansatz (customCode fuer seltene Einzelfaelle)

Haeufige Muster werden als eigene JSON-Felder modelliert (scanner, ssccScanner, wcsTelegram, brushConfig, correction). Seltene Einzelfaelle werden als customCode-Bloecke eingebettet:

{
  "id": "TRO117",
  "type": "1Sep",
  "fbType": "FB_ILS_MTRO_1Sep",
  "mainTroNo": "cMainTro117",
  "controlUnit": "OF1",
  "comment": "Clearing Station",
  "separator": {
    "no": "cSep117.1",
    "delayToNextItem": "TimeForSepWaiting_Short",
    "trailingTime": "T#100ms",
    "handlingTime": "T#50ms",
    "jamTime": "TimeForSepJam",
    "plugged": { "jam": true, "part": true, "scanner": true },
    "sensorInSep": "cInBG3300"
  },
  "sensorJam2": "cInBG3304",
  "scanner": {
    "id": "cScannerBX1100",
    "prefix": "bx1100",
    "hwResults": "BX1100~Ergebnisse_-_64_Bytes_1",
    "checkASCII": true,
    "timeout": "T#5s"
  },
  "correction": {
    "station": 0,
    "carrierExpect": "DB_JamArea0102.stJam0102_6.arCarrier[1]"
  },
  "customCode": {
    "beforeCall": [
      "#rTrig_ClarificationButton(CLK := \"SF0032\");"
    ],
    "releaseExpression": "#rTrig_ClarificationButton.Q",
    "afterCall": [
      "// Clearing-Station: Trolley loeschen",
      "IF NOT \"DB_Inputs\".Sensors[\"cInBG3300\"].xDirectSensor AND \"DB_Interface_HMI\".stClearingStation.xDeleteTrolley THEN",
      "    \"DB_JamArea0102\".stJam0102_6.arCarrier[1] := #stEmptyCarrier;",
      "    \"DB_Interface_HMI\".stClearingStation.xDeleteTrolley := FALSE;",
      "    #TRO117.nState := 100;",
      "END_IF;",
      "",
      "// Clearing-Station: Ladung loeschen",
      "IF NOT \"BG3301\" AND \"DB_Interface_HMI\".stClearingStation.xDeleteLoad THEN",
      "    \"DB_JamArea0102\".stJam0102_6.arCarrier[1].bStatus.%X1 := FALSE;",
      "    \"DB_Interface_HMI\".stClearingStation.xDeleteLoad := FALSE;",
      "END_IF;",
      "",
      "// HMI-Anzeige aktualisieren",
      "\"DB_Interface_HMI\".stClearingStation.stFirstCarrierInStation := \"DB_JamArea0102\".stJam0102_6.arCarrier[1];",
      "\"DB_Interface_HMI\".stClearingStation.xTrolleyInStation := \"DB_Inputs\".Sensors[\"cInBG3300\"].xDbncdSensor;"
    ]
  }
}

11. Connections — Physische Topologie (TRO-Verkettung)

Jede Verbindung beschreibt den Pfad: Quell-TRO + Exit-Slot → JamArea → Ziel-TRO + Entry-Slot. Switch-Ausgaenge haben nummerierte Exit-Slots (exit2, exit3); normale TROs haben nur exit.

"connections": [
  { "from": "TRO100",  "exitSlot": "exit",  "jamArea": "DB_JamArea0101.stJam0101_1", "to": "TRO101_IN", "entrySlot": "entry", "comment": "Eingang → Entry Buffer" },
  { "from": "TRO100",  "exitSlot": "exit",  "jamArea": "DB_JamArea0101.stJam0101_1", "to": "TRO101",    "entrySlot": "entry", "comment": "Parallel: direkt in EmptyBuffer" },
  { "from": "TRO101",  "exitSlot": "exit",  "jamArea": "DB_JamArea0102.stJam0102_2", "to": "TRO107",    "entrySlot": "entry", "comment": "EmptyBuffer → Switch Boom1" },
  { "from": "TRO102",  "exitSlot": "exit",  "jamArea": "DB_JamArea0102.stJam0102_1", "to": "TRO107",    "entrySlot": "entry" },
  { "from": "TRO107",  "exitSlot": "exit2", "jamArea": "DB_JamArea0103.stJam0103_1", "to": "TRO103",    "entrySlot": "entry", "direction": 1, "comment": "Dir1=LS1" },
  { "from": "TRO107",  "exitSlot": "exit3", "jamArea": "DB_JamArea0102.stJam0102_2", "to": "TRO112",    "entrySlot": "entry", "direction": 2, "comment": "Dir2=weiter" },
  { "from": "TRO103",  "exitSlot": "exit",  "jamArea": "DB_JamArea0104.stJam0104_1", "to": "TRO104",    "entrySlot": "entry" },
  { "from": "TRO104",  "exitSlot": "exit",  "jamArea": "DB_JamArea0104.stJam0104_2", "to": "LoadingBoom1", "entrySlot": "stopper" },
  { "from": "TRO106",  "exitSlot": "exit",  "jamArea": "DB_JamArea0102.stJam0102_2", "to": "TRO112",    "entrySlot": "entry", "comment": "LS1 Rueckleitung" },
  { "from": "TRO112",  "exitSlot": "exit2", "jamArea": "DB_JamArea0107.stJam0107_1", "to": "TRO108",    "entrySlot": "entry", "direction": 1, "comment": "Dir1=LS2" },
  { "from": "TRO112",  "exitSlot": "exit3", "jamArea": "DB_JamArea0102.stJam0102_3", "to": "TRO113",    "entrySlot": "entry", "direction": 2, "comment": "Dir2=Clearing" },
  { "from": "TRO111",  "exitSlot": "exit",  "jamArea": "DB_JamArea0102.stJam0102_3", "to": "TRO113",    "entrySlot": "entry", "comment": "LS2 Rueckleitung" },
  { "from": "TRO113",  "exitSlot": "exit",  "jamArea": "DB_JamArea0102.stJam0102_4", "to": "TRO114",    "entrySlot": "entry" },
  { "from": "TRO114",  "exitSlot": "exit2", "jamArea": "DB_JamArea4104.stJam4104_1", "to": null,         "entrySlot": null,    "direction": 1, "comment": "Dir1=InboundOut→WCS" },
  { "from": "TRO114",  "exitSlot": "exit3", "jamArea": "DB_JamArea0102.stJam0102_5", "to": "TRO116",    "entrySlot": "entry", "direction": 2, "comment": "Dir2=Clearing" }
]

Mehrwert connections:

  • Topologie-Validierung: Generator prueft ob jede in tros[].jamAreas genannte JamArea auch in connections erscheint
  • Topologie-Diagramme: Aus connections wird automatisch ein Mermaid-Flowchart erzeugt
  • Cross-Config-Vergleich: connections von UH01 vs UH04 direkt vergleichbar

12. Destinations — Abstrakte Routing-Tabelle

Beschreibt pro Carrier-Ziel: welche Switches wie geschaltet werden, den vollstaendigen TRO-Pfad und die Endaktion. Ermoeglicht automatische Generierung von FC_Direction ohne manuelles Pflegen von routing.switches.

"destinations": [
  {
    "id": "cDestInboundLS",
    "constant": 100,
    "description": "Carrier in Ladeschleife beladen (Loading Station 1 oder 2)",
    "routes": [
      {
        "id": "route_LS1",
        "description": "Weg zur Loading Station 1 (Boom 1)",
        "switchDecisions": [
          { "tro": "TRO107", "switch": "cSwi107.1", "direction": 1 },
          { "tro": "TRO112", "switch": "cSwi112.1", "direction": 2 }
        ],
        "path": ["TRO107", "TRO103", "TRO104", "LoadingBoom1", "TRO105", "TRO106"],
        "terminal": { "type": "loadingBoom", "element": "LoadingBoom1" }
      },
      {
        "id": "route_LS2",
        "description": "Weg zur Loading Station 2 (Boom 2)",
        "switchDecisions": [
          { "tro": "TRO107", "switch": "cSwi107.1", "direction": 2 },
          { "tro": "TRO112", "switch": "cSwi112.1", "direction": 1 }
        ],
        "path": ["TRO107", "TRO112", "TRO108", "TRO109", "LoadingBoom2", "TRO110", "TRO111"],
        "terminal": { "type": "loadingBoom", "element": "LoadingBoom2" }
      }
    ],
    "wcsTelegram": { "type": "DReqM", "decisionPoints": ["cDP_DOCK_01", "cDP_DOCK_02"] }
  },
  {
    "id": "cDestClearing",
    "constant": 200,
    "description": "Carrier zur Clearing-/Error-Station",
    "routes": [
      {
        "id": "route_clearing",
        "switchDecisions": [
          { "tro": "TRO107", "switch": "cSwi107.1", "direction": 2 },
          { "tro": "TRO112", "switch": "cSwi112.1", "direction": 2 },
          { "tro": "TRO114", "switch": "cSwi114.1", "direction": 2 }
        ],
        "path": ["TRO107", "TRO112", "TRO113", "TRO114", "TRO116", "TRO117"],
        "terminal": { "type": "clearingStation", "element": "TRO117" }
      }
    ]
  },
  {
    "id": "cDestInboundOut",
    "constant": 300,
    "description": "Carrier verlaesst das Inbound-System",
    "routes": [
      {
        "id": "route_exit",
        "switchDecisions": [
          { "tro": "TRO114", "switch": "cSwi114.1", "direction": 1 }
        ],
        "path": ["TRO113", "TRO114"],
        "terminal": { "type": "wcsTelegram", "action": "cSTRAIGHT", "decisionPoint": "cDP_INBOUND_OUT" }
      }
    ]
  },
  {
    "id": "cDestHighwayStorage",
    "constant": 400,
    "description": "Carrier faehrt zum Storage ueber Highway",
    "routes": [
      {
        "id": "route_storage",
        "switchDecisions": [
          { "tro": "TRO124", "switch": "cSwi124.1", "direction": 1 }
        ],
        "path": ["TRO113", "TRO114", "TRO120", "TRO121", "TRO122", "TRO123", "TRO124"],
        "terminal": { "type": "wcsTelegram", "action": "cSTORAGE", "decisionPoint": "cDP_HIGHWAY" }
      }
    ]
  }
]

Auswirkung auf bestehende Abschnitte:

Abschnitt Auswirkung
routing.switches[].rules Kann aus destinations[].routes[].switchDecisions abgeleitet werden (Single Source of Truth)
tros[].jamAreas Bleibt explizit fuer Debugging; Generator validiert Konsistenz gegen connections[]
FC_Direction (generiert) Wird kuenftig aus destinations statt aus routing.switches generiert

Mehrwert destinations:

  • FC_Direction auto-generieren: Switch-Regeln kommen direkt aus switchDecisions
  • Dokumentation: vollstaendiger Carrier-Pfad pro Ziel als Planungsgrundlage
  • Simulation: Carrier-Fluss kann ohne SPS per Graph-Traversal simuliert werden

13. Topologie-Graph UH01 — TRO-Ein- und Ausgänge

Jede Verbindung wird über eine JamArea realisiert. Abkürzung JAxxxx_y steht für "DB_JamAreaxxxx".stJamxxxx_y. Switch-TROs (Typ 1Sep1Swi) besitzen zwei Ausgänge (Dir1 / Dir2); ihre Richtungsentscheidung kommt aus FC_Direction.

Inbound-Hauptschleife (Mermaid-Diagramm)

flowchart LR
    classDef sep    fill:#d4e8ff,stroke:#3388cc
    classDef swi    fill:#ffe4a0,stroke:#cc8800
    classDef buf    fill:#d4f0d4,stroke:#338833
    classDef vario  fill:#e8d4f0,stroke:#883388
    classDef sscc   fill:#ffd4d4,stroke:#cc3333
    classDef ext    fill:#f0f0f0,stroke:#888,stroke-dasharray:5

    EXT_IN([Externer Eingang]):::ext
    EXT_OUT([InboundOut to WCS]):::ext

    EXT_IN        -->|JA0100_1| TRO100:::sep
    TRO100        -->|JA0101_1| TRO101_IN:::sep
    TRO101_IN     -->|JamBuf101| TRO101[TRO101 EmptyBuf]:::buf
    TRO101_IN     -->|JA0101_2| TRO102_IN:::sep
    TRO102_IN     -->|JamBuf102| TRO102[TRO102 EmptyBuf]:::buf
    TRO101        -->|JA0102_2| TRO112:::swi
    TRO102        -->|JA0102_1| TRO107:::swi

    TRO107        -->|Dir1 JA0103_1| TRO103:::sep
    TRO107        -->|Dir2 JA0102_2| TRO112
    TRO103        -->|JA0104_1| TRO104:::sep
    TRO104        -->|JA0104_2| LB1([LoadingBoom 1]):::ext
    LB1           -->|JA0104_3| TRO105:::sscc
    TRO105        -->|JA0106_2| TRO106:::sep
    TRO106        -->|JA0102_2| TRO112

    TRO112        -->|Dir1 JA0107_1| TRO108:::sep
    TRO112        -->|Dir2 JA0102_3| TRO113:::sep
    TRO108        -->|JA0108_1| TRO109:::sep
    TRO109        -->|JA0108_2| LB2([LoadingBoom 2]):::ext
    LB2           -->|JA0108_3| TRO110:::sscc
    TRO110        -->|JA0110_2| TRO111:::sep
    TRO111        -->|JA0102_3| TRO113

    TRO113        -->|JA0102_4| TRO114:::swi
    TRO114        -->|Dir1 JA4104_1| TRO115:::vario
    TRO115        -->                    EXT_OUT
    TRO114        -->|Dir2 JA0102_5| TRO116:::sep
    TRO116        -->|JA0102_6| TRO117:::sep
    TRO117        -.->|JA0102_1 Clearing-Rückf.| TRO107

Highway / Storage-Verbindungen (Mermaid-Diagramm)

flowchart LR
    classDef sep    fill:#d4e8ff,stroke:#3388cc
    classDef swi    fill:#ffe4a0,stroke:#cc8800
    classDef vario  fill:#e8d4f0,stroke:#883388
    classDef ext    fill:#f0f0f0,stroke:#888,stroke-dasharray:5

    HWY_IN([Highway Loaded In]):::ext     -->|JA4103_1| TRO120:::vario
    ST_IN1([Storage Empty In]):::ext      -->|JA4503_1| TRO121:::vario
    ST_IN1                                -->|JA4503_2| TRO122:::sep
    TRO122                                -->|JA4502_1| TRO123:::vario
    BORNER1([Borner Eingang 1]):::ext     -->|JA4502_2| TRO124:::swi
    TRO124 -->|Dir1 JA4204_2| TRO125:::sep
    TRO125 -->|JA4203_1| TRO126:::vario
    TRO126 -->                STORAGE([Storage]):::ext
    TRO124 -->|Dir2 JA4501_1| TRO127:::vario
    EMPTY_IN([Leere Carrier von Highway]):::ext -->|JA4501_2| TRO128:::vario
    BORNER2([Borner Eingang 2]):::ext     -->|JA4302_2| TRO129:::sep
    TRO129                                -->|JA4204_1| TRO130:::sep
    TRO130                                -->|JA4501_1| TRO127
    AMR_IN([Loaded to AMR]):::ext         -->|JA4403_1| TRO131:::vario
    TRO131                                -->            AMR([AMR-System]):::ext
    HWY_IN2([Highway Eingang 2]):::ext    -->|JA4302_1| TRO133:::vario
    AMR_HWY([AMR Highway]):::ext          -->|JA4402_1| TRO134:::vario

TRO-Tabelle: Zone A — Eingang / Leere-Carrier-Puffer

TRO Typ Beschreibung Eingang JamArea Eingang von Ausgang JamArea Ausgang zu
TRO100 1Sep Anlageneingang JA0100.stJam0100_1 Externer Eingang JA0101.stJam0101_1 TRO101_IN
TRO101_IN 1Sep Separator Empty Buffer rechts JA0101.stJam0101_1 TRO100 DB_JamBuffer101 / JA0101.stJam0101_2 TRO101 / TRO102_IN
TRO101 EmptyCarrBuffer Leere-Carrier-Puffer rechts DB_JamBuffer101 TRO101_IN JA0102.stJam0102_2 TRO112
TRO102_IN 1Sep Separator Empty Buffer links JA0101.stJam0101_2 TRO101_IN DB_JamBuffer102 TRO102
TRO102 EmptyCarrBuffer Leere-Carrier-Puffer links DB_JamBuffer102 TRO102_IN JA0102.stJam0102_1 TRO107

TRO-Tabelle: Zone B — Loading Station 1

TRO Typ Beschreibung Eingang JamArea Eingang von Ausgang JamArea Ausgang zu
TRO103 1Sep Zufahrt Loading Station 1 JA0103.stJam0103_1 TRO107 (Dir1) JA0104.stJam0104_1 TRO104
TRO104 1Sep Vorstopper LS1 + Barcode-Scanner JA0104.stJam0104_1 TRO103 JA0104.stJam0104_2 LoadingBoom1 (Stopper)
TRO105 1Sep_SSCC SSCC-Scanner nach LS1 JA0104.stJam0104_3 LoadingBoom1 (nach Beladung) JA0106.stJam0106_2 TRO106
TRO106 1Sep Abfuhr Loading Station 1 JA0106.stJam0106_2 TRO105 JA0102.stJam0102_2 TRO112

TRO-Tabelle: Zone C — Loading Station 2

TRO Typ Beschreibung Eingang JamArea Eingang von Ausgang JamArea Ausgang zu
TRO108 1Sep Zufahrt Loading Station 2 JA0107.stJam0107_1 TRO112 (Dir1) JA0108.stJam0108_1 TRO109
TRO109 1Sep Vorstopper LS2 + Barcode-Scanner JA0108.stJam0108_1 TRO108 JA0108.stJam0108_2 LoadingBoom2 (Stopper)
TRO110 1Sep_SSCC SSCC-Scanner nach LS2 JA0108.stJam0108_3 LoadingBoom2 (nach Beladung) JA0110.stJam0110_2 TRO111
TRO111 1Sep Abfuhr Loading Station 2 JA0110.stJam0110_2 TRO110 JA0102.stJam0102_3 TRO113

TRO-Tabelle: Zone D — Switches / Hauptrouting

TRO Typ Beschreibung Eingang JamArea Eingang von Ausgang Dir1 Ausgang Dir2
TRO107 1Sep1Swi Switch: LS1 / LS2+Clearing JA0102.stJam0102_1 TRO102, TRO117 (Rückf.) JA0103.stJam0103_1 → TRO103 JA0102.stJam0102_2 → TRO112
TRO112 1Sep1Swi Switch: LS2 / Clearing+Ausgang JA0102.stJam0102_2 TRO101, TRO106, TRO107(D2) JA0107.stJam0107_1 → TRO108 JA0102.stJam0102_3 → TRO113
TRO113 1Sep Zufahrt Clearing + Barcode-Scanner JA0102.stJam0102_3 TRO111, TRO112 (Dir2) JA0102.stJam0102_4 → TRO114 —
TRO114 1Sep1Swi Switch: InboundOut / Clearing + Scanner JA0102.stJam0102_4 TRO113 JA4104.stJam4104_1 → TRO115 JA0102.stJam0102_5 → TRO116

TRO-Tabelle: Zone E — Clearing-Station

TRO Typ Beschreibung Eingang JamArea Eingang von Ausgang JamArea Ausgang zu
TRO116 1Sep Zufahrt Clearing-Station JA0102.stJam0102_5 TRO114 (Dir2) JA0102.stJam0102_6 TRO117
TRO117 1Sep Clearing-Station (HMI + customCode) JA0102.stJam0102_6 TRO116 JA0102.stJam0102_1 TRO107 (Clearing-Rückführung)

TRO-Tabelle: Zone F — InboundOut

TRO Typ Beschreibung Eingang JamArea Eingang von Ausgang Ausgang zu
TRO115 Vario Übergabe InboundOut JA4104.stJam4104_1 TRO114 (Dir1) WCS-Telegramm Externes System (WCS/UH04)

TRO-Tabelle: Zone G — Highway / Storage (Cross-UH-Verbindungen)

TRO Typ Beschreibung Eingang JamArea Eingang von Ausgang JamArea Ausgang zu
TRO120 Vario Loaded Carrier von Highway eingehend JA4103.stJam4103_1 Highway-Extern — Borner-Einspeisung
TRO121 Vario Eingang Speicher-Kreislauf 1 JA4503.stJam4503_1 Extern — —
TRO122 1Sep Speicher-Transition JA4503.stJam4503_2 Extern JA4502.stJam4502_1 TRO123
TRO123 Vario Speicher-Übergabe JA4502.stJam4502_1 TRO122 — —
TRO124 1Sep1Swi Switch: Carousel / Highway-Storage JA4502.stJam4502_2 Extern Dir1: JA4204.stJam4204_2 → TRO125 Dir2: JA4501.stJam4501_1 → TRO127
TRO125 1Sep Highway-Exit Richtung Carousel JA4204.stJam4204_2 TRO124 (Dir1) JA4203.stJam4203_1 TRO126
TRO126 Vario Leere Carrier → Storage JA4203.stJam4203_1 TRO125 — Storage
TRO127 Vario Highway-Ausgang JA4501.stJam4501_1 TRO124(D2), TRO130 — —
TRO128 Vario Leere Carrier → Inbound (von Highway) JA4501.stJam4501_2 Extern — —
TRO129 1Sep Borner-Eingang Seite 2 JA4302.stJam4302_2 Extern JA4204.stJam4204_1 TRO130
TRO130 1Sep Transition zu Highway JA4204.stJam4204_1 TRO129 JA4501.stJam4501_1 TRO127
TRO131 Vario Loaded Carrier → AMR JA4403.stJam4403_1 Extern — AMR-System
TRO132 1Sep (auskommentiert — nicht aktiv) — — — —
TRO133 Vario Highway-Eingang 2 JA4302.stJam4302_1 Extern — —
TRO134 Vario AMR Highway JA4402.stJam4402_1 Extern — —

14. Erweiterungen aus der E/A-Listen- und Positionsdaten-Analyse

Die Analyse der Eingabelisten in data/Eingaben/ (siehe EA-Listen-Analyse.md) hat gezeigt, dass grosse Teile des JSON automatisch aus den Projektierungsdaten befuellbar sind. Dafuer werden folgende Schema-Erweiterungen eingefuehrt:

14.1 Feld unit je TRO/Conveyor (Schluessel zur E/A-Liste)

Jede TRO-/Conveyor-Instanz erhaelt die Foerdertechnik-Einheit (M-Nummer) als expliziten Schluessel. Die M-Nummern stehen in den Kommentaren der E/A-Listen und identisch in den REGION-Namen des SCL-Codes:

{
  "id": "TRO115",
  "unit": "M4104",
  "unitKind": "CV",
  "type": "Vario",
  "pos": { "x": 341906, "y": 164862 },
  "cabinet": "UC1101"
}
Feld Quelle Bedeutung
unit Kommentar E/A-Liste ((ILS-CV M4104)) M-Nummer der mechanischen Einheit
unitKind dito KR = Kreisel/Carousel, CV = Conveyor, K = Kreisel-Einfahrt
pos ..._positions.json -> sensors[<BMK>@<SPS>].pos x/y-Lage in mm (Referenzsensor der Einheit)
cabinet ..._positions.json -> mappings Verteiler/Schaltschrank aus der realen Verkabelung

14.2 Gruppierungsebene areas

Neue Top-Level-Ebene, die TROs/Conveyors zu den in den Listen gefundenen Bereichsgruppen buendelt:

"areas": [
  {
    "id": "Block 1.1.1",
    "kind": "pinStoreBlock",
    "members": ["TRO208", "TRO209", "TRO210"],
    "ucStations": ["UC2101"],
    "safetyZone": "UZ0201",
    "storageDb": "DB_Storage1.1.1",
    "lines": 8
  },
  {
    "id": "LS1",
    "kind": "loadingStation",
    "members": ["TRO103", "TRO104", "TRO105", "TRO106", "LoadingBoom1"],
    "safetyZone": "UZ0110"
  },
  {
    "id": "WS1.1",
    "kind": "workStation",
    "members": ["TRO421"]
  }
]

Gefundene kind-Werte: pinStoreBlock (Block x.y.z, UH02/UH03), loadingStation (LS 1/2, UH01), workStation (WS x.y, UH04/UH05), safetyZone (UZ0x0y), ucStation (Feldstation/Verteiler).

14.3 Rollenklassifikation ueber das VERW-Vokabular

Die Positions-JSONs (..._positions.json) enthalten je Signal das Feld VERW — ein kontrolliertes Vokabular, das zuverlaessiger ist als das Parsen der freien Kommentartexte:

VERW-Wert Rolle im JSON Hinweis auf FB-Typ
In sep separator.sensorInSep —
Sep outputs.stopper* (MB-Ausgang) —
Jam detector / Jam detector (LP) sensorJam* —
ES branch outputs.sw*ExTo* (Weichenausgang) 1SepNSwi
conveyor full vario.sensors.jam / Puffer voll Vario
MT in Position vario.sensors.carrInPos Vario
Finger in position vario.sensors.finger Vario
PIN query PinStore-Abfrage PinStore_Auto
Sync P1..P4 Synchronisationspunkte PinStore/Vario-Sonderform
Rad dreht LoadingBoom Rad-Sensor LoadingBoom

Heuristik fuer den FB-Typ je Einheit: ES branch vorhanden -> Weiche; Finger/MT in Position/conveyor full -> Vario; PIN query -> PinStore_Auto; Anzahl In sep (1/2) -> 1Sep/2Sep; nur FC/MA-Paar ohne Separator -> FB_Conveyor.

14.4 Quellen-Uebersicht

Datenquelle Liefert
..._TIA.xlsx "PLC Tags" BMK-Name, Datentyp, %E/%A-Adresse, Kommentar -> sensors[], outputs
..._TIA.xlsx "Constants" cIn...-Indexkonstanten -> Konstanten-Tabelle, sensors[].constant
..._WSCAD.xlsx "Bezug" Ortskennzeichen =A01+UCxxxx-KF1DIx -> Karten-/Stationszuordnung
..._positions.json pos (x/y), VERW (Rolle), mappings (Signal->Verteiler), distributors (Verteiler-Position)
..._todraw.json Kabelwege und -laengen (Doku/BOM, nicht SPS-relevant)

Nicht aus den Listen ableitbar bleiben: Timings, Priority-Manager, Release-Ausdruecke, Scanner-Zuordnung (BX = PROFINET), customCode und die Verkettungsrichtung der Topologie (connections/destinations). Die Positionen dienen dabei als Plausibilitaets-Check der Topologie (kurze Abstaende = wahrscheinliche Nachbarn) und fuer massstabsgetreue Lageplaene.

14.5 Skeleton-Generator

Das Skript lib/create_skel.py (Aufruf ueber bin\create_skel.bat) liest die Eingabelisten und erzeugt je Steuerung ein Skeleton der JSON-Zwischendatei (results/skeleton_UH0x.json) sowie ein SCL-Grundgeruest. Die SCL-Aufruf-Templates sind als globale Definitionen im Skript hinterlegt und koennen spaeter in eine .cfg ausgelagert werden.

Welche SCL-Bausteine werden daraus generiert?

Ziel-Baustein Generiert aus JSON-Abschnitt
FB_Main VAR-Deklaration conveyors[], tros[], loadingBooms[], emptyCarrBuffers[]
FB_Main REGION Conveyor conveyors[] — Settings + Call-Pattern je Subtype
FB_Main REGION TRO tros[] — Separator-Settings + Call je fbType
FB_Main REGION LoadingBoom loadingBooms[] — Controls/Boom/Foot/Call/Outputs
FB_Main REGION EmptyCarrBuffer emptyCarrBuffers[] — Lines/Jams/Call
FB_Main REGION Reinitialisieren alle tros[].mainTroNo + emptyCarrBuffers[].mainTroNo
FB_CallSensors sensors[] — repetitiver Call-Block pro Sensor
FC_Direction routing.switches[] — CASE-Statement
FC_Call_Jams jamAreas[] — Jam-Aufrufe
FC_CARR_GLOB_CORRECTION TROs mit correction-Feld
Konstanten-Tabelle Alle constant-Felder — TIA-Konstantenliste

Vorteile

  1. Single Source of Truth: Aenderung an einem Ort (JSON) statt in 5 verschiedenen 3000-9000 Zeilen SCL-Dateien
  2. Fehlerreduktion: Kein Copy-Paste mehr zwischen UH01-UH05
  3. Review: Topologie-Aenderungen sind als JSON-Diff lesbar
  4. Neues Projekt: Nur neue JSON-Datei anlegen, Code wird generiert
  5. Validierung: JSON-Schema kann Pflichtfelder, gueltige Typen etc. pruefen

Sonderlogik-Behandlung (Hybrid-Ansatz)

Muster Haeufigkeit Behandlung
Scanner + Correction 5x pro UH Eigene JSON-Felder (scanner, correction)
SSCC-Scanner + WCS-Telegramm 2x pro UH Eigene JSON-Felder (ssccScanner, wcsTelegram)
Buersten-Taktlogik 4x in UH01 Eigenes JSON-Feld (brushConfig)
Priority Manager ~10x pro UH Eigenes JSON-Feld (priority)
Clearing-Station (Delete-Buttons) 1x in UH01 customCode.afterCall
Laengenmessung DReqM 1x in UH01/UH05 customCode.afterCall

Offene Designentscheidungen

  1. Ausdruck-Sprache: Felder wie release enthalten SCL-Ausdruecke (#fbLoadingBoom1.xOutReady AND ...). Diese werden als Strings durchgereicht.

  2. Generator: Falls gewuenscht, Python + Jinja2-Templates als bin/generate_scl.py im Repository.

  3. JamArea-Kapazitaeten: Koennten vollstaendig in die JSON aufgenommen werden, um auch die JamArea-DBs zu generieren.

  4. Topologie-Verbindungen: Die JSON beschreibt aktuell jedes Element isoliert. Optional koennte ein connections-Abschnitt die Verkettung (TRO100 -> JamArea0101 -> TRO101_IN -> Buffer -> TRO101 -> JamArea0102 -> ...) explizit machen.

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