OpenCIM User Manual Ver.4.7

OpenCIM
OpenCIM Offline and OpenFMS
Computer Integrated Manufacturing

for Industrial Training Applications
Software Version 4.7
User Manual
Catalog No. 100094 Rev. I
Copyright 2015 by Intelitek Inc.
OpenCIM User Manual
Cat.# 100094 Rev. I
August 2015
All rights reserved. No part of this publication may be stored in a retrieval system, or
reproduced in any way, including but not limited to photocopy, photography, magnetic or
other recording, without the prior agreement and written permission of the publisher.
Program listings may be entered, stored and executed in a computer system, but not
reproduced for publication.
This manual is designed to provide information about the OpenCIM, OpenFMS, and
OpenCIM Offline system and software. Every effort has been made to make this book
complete and as accurate as possible. However, no warranty of suitability, purpose or fitness
is made or implied. Intelitek Inc. is not liable or responsible to any person or entity for loss
or damage in connection with or stemming from the use of OpenCIM, OpenFMS,
OpenCIM Offline and/or the information contained in this publication
Intelitek Inc. bears no responsibility for errors which may appear in this publication and
retains the right to make changes to the software and manual without prior notice.
INTELITEK INC.
Tel: (603) 413-2600
Fax: (603) 625-2137
e-mail: [email protected]
web site: www.intelitek.com
Table of Contents
1 .............................................................................................................................. 1-1
Introduction ....................................................................................................................................................... 1-1

About CIM ...................................................................................................................................................... 1-2
About OpenCIM.............................................................................................................................................. 1-3
About This Manual ......................................................................................................................................... 1-4
How This Manual is Organized .................................................................................................................. 1-5
Who Should Use This Manual ........................................................................................................................ 1-6
How to Use This Manual ................................................................................................................................ 1-7
2 .............................................................................................................................. 2-1
System Overview................................................................................................................................................ 2-1

OpenCIM Description ..................................................................................................................................... 2-2
Unique Features .......................................................................................................................................... 2-2
OpenCIM Additional Software Packages ................................................................................................... 2-3
Production Operations ..................................................................................................................................... 2-4
OpenCIM Sample Application - The Covered Box .................................................................................... 2-4
Components of the OpenCIM Cell .................................................................................................................. 2-6
Stations ............................................................................................................................................................ 2-7
Material Flow in the OpenCIM Cell ............................................................................................................... 2-9
Templates .................................................................................................................................................... 2-9
Storage ...................................................................................................................................................... 2-10
Conveyor and Pallets ................................................................................................................................ 2-11
Robots and Controllers ............................................................................................................................. 2-12
Processing Machines ................................................................................................................................. 2-13
CIM Control & Optimization ........................................................................................................................ 2-14
What is Optimization? .............................................................................................................................. 2-14
CIM Definition Modules........................................................................................................................... 2-15
The CIM Manager .................................................................................................................................... 2-15
The Station Manager ................................................................................................................................. 2-15
PC Requirements in OpenCIM ................................................................................................................. 2-16
Device Drivers .............................................................................................................................................. 2-19
Robotic Device Drivers............................................................................................................................. 2-20
CNC Machine Device Driver .................................................................................................................... 2-21
PLC Device Driver ................................................................................................................................... 2-23
Quality Control Device Drivers ................................................................................................................ 2-23
Hydraulic Workstation Device Drivers ..................................................................................................... 2-24
Pneumatic WorkStation Device Drivers ................................................................................................... 2-24
Process Workstation Device Drivers ........................................................................................................ 2-24
OpenCIM Communication Network ............................................................................................................. 2-25
LAN .......................................................................................................................................................... 2-26
RS232 ....................................................................................................................................................... 2-27
Inputs/Outputs ........................................................................................................................................... 2-27
Integration ..................................................................................................................................................... 2-28
3 .............................................................................................................................. 3-1
Safety .................................................................................................................................................................. 3-1

General Safety Rules ....................................................................................................................................... 3-2
Robot and Controller Safety ............................................................................................................................ 3-3
CNC Machine Safety ...................................................................................................................................... 3-4
ASRS Safety.................................................................................................................................................... 3-5
User Manual i OpenCIM

Table of Contents
ASRS Carousel ........................................................................................................................................... 3-5
ASRS2 and ASRS-36 .................................................................................................................................. 3-5
ASRS-36u and ASRS-36uX2 ..................................................................................................................... 3-5
Conveyor and PLC Safety ............................................................................................................................... 3-6
4 .............................................................................................................................. 4-1
Installation.......................................................................................................................................................... 4-1
OpenCIM Installation Workflow .................................................................................................................... 4-2
Hardware Installation ...................................................................................................................................... 4-3
Conveyor and Pallets .................................................................................................................................. 4-3
Robots and Robot Controllers ..................................................................................................................... 4-3
ASRS .......................................................................................................................................................... 4-3
Barcode Reader ........................................................................................................................................... 4-3
RFID Reader ............................................................................................................................................... 4-4
Pneumatic Devices ...................................................................................................................................... 4-4
Palletizing Racks and Buffers ..................................................................................................................... 4-4
Templates .................................................................................................................................................... 4-4
Wiring ............................................................................................................................................................. 4-5
Software Installation ....................................................................................................................................... 4-6
Installing the OpenCIM Software ............................................................................................................... 4-7
Installing OpenCIM Projects .................................................................................................................... 4-14
Manual Web Viewer Installation .............................................................................................................. 4-18
Software for Workstation PCs .................................................................................................................. 4-28
Robot Positions and Homing ......................................................................................................................... 4-39
Homing the Robot from the ACL Controller ............................................................................................ 4-39
Homing the Robot from Scorbase ............................................................................................................. 4-40
System Check ................................................................................................................................................ 4-41
5 .............................................................................................................................. 5-1
Project Manager ................................................................................................................................................ 5-1

Accessing the Project Manager ....................................................................................................................... 5-2
Project Manager Main Window ...................................................................................................................... 5-3
Project Manager Toolbar ............................................................................................................................ 5-5
3D Model Display Area .............................................................................................................................. 5-7
Project Manager User Mode ......................................................................................................................... 5-10
Adding Projects......................................................................................................................................... 5-10
Importing Projects..................................................................................................................................... 5-10
Loading All Projects ................................................................................................................................. 5-11
Copying Projects ....................................................................................................................................... 5-11
Removing Projects .................................................................................................................................... 5-12
Accessing CIM Manager .......................................................................................................................... 5-12
Accessing CIM Setup ............................................................................................................................... 5-12
Project Manager Administration Mode ......................................................................................................... 5-13
Defining Administrator Access Rights ..................................................................................................... 5-13
Moving Projects to Archive ...................................................................................................................... 5-13
Moving Projects to User Projects tab ........................................................................................................ 5-13
Installing the Web Viewer Server ................................................................................................................. 5-14
6 .............................................................................................................................. 6-1
Operating CIM Manager .................................................................................................................................. 6-1

Accessing the CIM Manager ........................................................................................................................... 6-2
CIM Manager Main Window .......................................................................................................................... 6-3
CIM Manager Toolbar ................................................................................................................................ 6-5
CIM Manager Time Counter....................................................................................................................... 6-7
PLC Status Bar............................................................................................................................................ 6-7
User Manual ii OpenCIM

Table of Contents
Viewing Area .............................................................................................................................................. 6-7
Order View ................................................................................................................................................. 6-7
Device View ............................................................................................................................................... 6-7
Status Bar .................................................................................................................................................... 6-7
Information Bar........................................................................................................................................... 6-7
CIM Operational Modes.................................................................................................................................. 6-8
CIM Modes Dialog Box.............................................................................................................................. 6-8
CIM Manager Views ..................................................................................................................................... 6-13
Order View ............................................................................................................................................... 6-13
Storage View............................................................................................................................................. 6-14
Program View ........................................................................................................................................... 6-15
Device View ............................................................................................................................................. 6-16
Log View .................................................................................................................................................. 6-17
Machine Queue View ............................................................................................................................... 6-17
Pallet View................................................................................................................................................ 6-18
Leaf View ................................................................................................................................................. 6-18
Event View ............................................................................................................................................... 6-20
Message History ....................................................................................................................................... 6-20
CIM Scheduler .............................................................................................................................................. 6-21
Creating a Planned Production Schedule .................................................................................................. 6-23
Graphic Display and Tracking ...................................................................................................................... 6-24
Status Messages ........................................................................................................................................ 6-24
Updating the Display ................................................................................................................................ 6-24
7 .............................................................................................................................. 7-1
CIM Manager Utility Programs ....................................................................................................................... 7-1

Machine and Process Definitions .................................................................................................................... 7-2
Machine Definition Window ...................................................................................................................... 7-3
Machine Process Table ............................................................................................................................... 7-4
Part Definition ................................................................................................................................................. 7-9
Part Definition Form ................................................................................................................................. 7-11
Part Table .................................................................................................................................................. 7-15
Storage Definition ......................................................................................................................................... 7-22
Storage Manager Form ............................................................................................................................. 7-22
Storage Data Table.................................................................................................................................... 7-24
MRP .............................................................................................................................................................. 7-31
About MRP ............................................................................................................................................... 7-31
About OpenCIM MRP .............................................................................................................................. 7-31
Customer Order Form ............................................................................................................................... 7-32
Manufacturing Order Form ....................................................................................................................... 7-34
Purchase Order Form ................................................................................................................................ 7-37
Optimization .................................................................................................................................................. 7-40
CIM Optimization Definition.................................................................................................................... 7-40
CIM Optimization Definition Window ..................................................................................................... 7-41
Additional Optimization Methods in OpenCIM ....................................................................................... 7-46
Benefits of the Optimization Approach .................................................................................................... 7-50
Performance Analysis ................................................................................................................................... 7-51
CIM Performance Analysis....................................................................................................................... 7-51
CIM Performance Analysis Window ........................................................................................................ 7-52
Reports .......................................................................................................................................................... 7-59
Part Definition Report ............................................................................................................................... 7-60
Subpart Report .......................................................................................................................................... 7-61
Manufacturing Order Report..................................................................................................................... 7-62
Machine Report......................................................................................................................................... 7-63
Process Report .......................................................................................................................................... 7-64
ASRS Report............................................................................................................................................. 7-65
Analysis Report......................................................................................................................................... 7-66
Location Status Report .............................................................................................................................. 7-68
User Manual iii OpenCIM

Table of Contents
A-Plan Report ........................................................................................................................................... 7-69
Purchase Order Report .............................................................................................................................. 7-70
User-Defined Report ................................................................................................................................. 7-70
8 .............................................................................................................................. 8-1
Virtual CIM Setup ............................................................................................................................................. 8-1

CIM Setup Overview ...................................................................................................................................... 8-2
Virtual CIM Setup Limitations ................................................................................................................... 8-2
Accessing CIM Setup ...................................................................................................................................... 8-3
CIM Setup Main Window ............................................................................................................................... 8-4
Virtual CIM Setup Menu Bar...................................................................................................................... 8-5
Edit Menu ................................................................................................................................................... 8-6
View Menu ................................................................................................................................................. 8-7
Configuration Parameters Popup Menus .................................................................................................... 8-9
Working with the CIM Setup ........................................................................................................................ 8-14
Creating a User Defined Conveyor ........................................................................................................... 8-14
Creating a Rectangular Conveyor ............................................................................................................. 8-17
Creating an L-Shaped Conveyor ............................................................................................................... 8-18
Adding Stations......................................................................................................................................... 8-19
Adding Tables ........................................................................................................................................... 8-20
Adding Robots .......................................................................................................................................... 8-22
Manipulating the Graphic Display ............................................................................................................ 8-22
Changing the Focus of the Graphic Display ............................................................................................. 8-23
Tutorial .......................................................................................................................................................... 8-24
Stage 1: Designing the CIM Cell .............................................................................................................. 8-24
Stage 2: Operating the CIM Cell............................................................................................................... 8-30
9 .............................................................................................................................. 9-1
OpenCIM Device Drivers.................................................................................................................................. 9-1

Overview of Device Drivers............................................................................................................................ 9-2
Device Driver Control Panel ........................................................................................................................... 9-3
Modes of Operation......................................................................................................................................... 9-4
Device Driver Loading Options .................................................................................................................. 9-5
CNC Device Driver ......................................................................................................................................... 9-6
Running the CNC Device Driver ................................................................................................................ 9-6
Downloading G-Code ................................................................................................................................. 9-8
The CNC Control Panel .............................................................................................................................. 9-9
Robotic Device Drivers ................................................................................................................................. 9-12
Quality Control Device Drivers .................................................................................................................... 9-18
The QC Control Panel ............................................................................................................................... 9-20
QC Device Settings ................................................................................................................................... 9-23
ViewFlex Device Driver ............................................................................................................................... 9-24
Adjustments .............................................................................................................................................. 9-24
Sample Script ............................................................................................................................................ 9-25
ULS Device Driver ....................................................................................................................................... 9-27
Downloading Print Files ........................................................................................................................... 9-27
User Interface ............................................................................................................................................ 9-28
Setting the Zero Point ............................................................................................................................... 9-29
Control Modes .......................................................................................................................................... 9-30
BCR Device Driver ....................................................................................................................................... 9-32
User Interface ............................................................................................................................................ 9-32
Control Modes .......................................................................................................................................... 9-33
RFID Device Driver ...................................................................................................................................... 9-37
User Interface ............................................................................................................................................ 9-37
Control Modes .......................................................................................................................................... 9-38
PLC Device Driver ........................................................................................................................................ 9-40
PLC Messages........................................................................................................................................... 9-41
User Manual iv OpenCIM

Table of Contents
PLC Control Panel .................................................................................................................................... 9-43
Simulating a Conveyor ............................................................................................................................. 9-45
Hydraulic Device Driver ............................................................................................................................... 9-46
Installing the Hydraulic Device Driver ..................................................................................................... 9-46
Testing the Hydraulic Device Driver in CIM (Standalone Mode) ............................................................ 9-48
Operating the Hydraulic Device Driver in OpenCIM (Real Mode) .......................................................... 9-50
(Optional) Operating the Hydraulic Device Driver in OpenCIM (Offline) .............................................. 9-51
Pneumatic Device Driver .............................................................................................................................. 9-53
Installing the Vuniq Software ................................................................................................................... 9-53
Configuring the Vuniq Application Settings............................................................................................. 9-55
Operating the Pneumatic Device Driver in OpenCIM - Real Mode ......................................................... 9-57
Pneumatic Station Troubleshooting .......................................................................................................... 9-58
Process Device Driver ................................................................................................................................... 9-60
Installing the Vuniq Software ................................................................................................................... 9-60
Configuring the Vuniq Application Settings............................................................................................. 9-62
Operating the Process Device Driver in OpenCIM - Real Mode .............................................................. 9-64
Viewing the Processing Station Information ............................................................................................ 9-66
Process Station Troubleshooting ............................................................................................................... 9-67
10 .......................................................................................................................... 10-1
Web Viewer ...................................................................................................................................................... 10-1
Installing the Client ....................................................................................................................................... 10-2
Accessing the Web Viewer ........................................................................................................................... 10-4
Web Viewer Main Window .......................................................................................................................... 10-5
Graphic Display Tab ................................................................................................................................. 10-5
View Scheduler Tab.................................................................................................................................. 10-6
View Program Tab .................................................................................................................................... 10-6
View Leaf Tab .......................................................................................................................................... 10-7
View Order Tab ........................................................................................................................................ 10-7
View Storage Tab ..................................................................................................................................... 10-8
View Device Tab ...................................................................................................................................... 10-9
View Pallet Tab ........................................................................................................................................ 10-9
Web Viewer Status Bar ........................................................................................................................... 10-10
View About Tab...................................................................................................................................... 10-11
11 .......................................................................................................................... 11-1
OpenCIM Programming ................................................................................................................................. 11-1

Robotic Programming for OpenCIM ............................................................................................................ 11-2
The Pick-and-Place Strategy ..................................................................................................................... 11-2
Overview of a Pick-and-Place Command ................................................................................................. 11-4
Teaching Robot Positions ......................................................................................................................... 11-5
Writing Scorbase Source Code ................................................................................................................. 11-9
Writing ACL Source Code...................................................................................................................... 11-11
QC Programs........................................................................................................................................... 11-23
ACL Off-Line Utilities ........................................................................................................................... 11-25
Adding a New Pick-and-Place Operation ............................................................................................... 11-28
CNC Programming for OpenCIM ............................................................................................................... 11-33
CNC Script Language ............................................................................................................................. 11-33
CNC Script Language Commands .......................................................................................................... 11-39
Robot and CNC Interface ............................................................................................................................ 11-54
Writing Scorbase Programs for the CNC Machine ................................................................................. 11-57
Writing ACL Programs for the CNC Machine ....................................................................................... 11-59
Using CNC Script Programs for ACL Program Response...................................................................... 11-64
Adjustments for Single Robots Tending Two Machines ........................................................................ 11-65
ACL Controller Backup and Restore ...................................................................................................... 11-65
Optimization Enhancement Using Open Source ......................................................................................... 11-67
Experimenting with Production Strategies Using the A-Plan ..................................................................... 11-68
User Manual v OpenCIM

Table of Contents
A-Plan Commands .................................................................................................................................. 11-68
12 .......................................................................................................................... 12-1
Inside OpenCIM .............................................................................................................................................. 12-1

OpenCIM Loader: DDLoader.EXE .............................................................................................................. 12-2
OpenCIM Directory Structure ....................................................................................................................... 12-5
MAP.INI ................................................................................................................................................. 12-13
SETUP.CIM............................................................................................................................................ 12-15
DEVICE.DMC ........................................................................................................................................ 12-18
INI Files .................................................................................................................................................. 12-19
VC2_WM.DBF ....................................................................................................................................... 12-30
OpenCIM Database Structure ..................................................................................................................... 12-32
Application to Report File Cross Reference ........................................................................................... 12-38
Software Backup ......................................................................................................................................... 12-40
13 .......................................................................................................................... 13-1
Errors and Troubleshooting ........................................................................................................................... 13-1

Device Error Handling .................................................................................................................................. 13-2
Where the Problem Occurred.................................................................................................................... 13-2
What the Problem Is.................................................................................................................................. 13-3
How to Proceed......................................................................................................................................... 13-3
How to Recover a Failed Device .............................................................................................................. 13-5
Troubleshooting ............................................................................................................................................ 13-6
Error Messages ............................................................................................................................................ 13-10
Contacting Technical Support ..................................................................................................................... 13-14
Problem Report Form ............................................................................................................................. 13-15
14 .......................................................................................................................... 14-1
Glossary ............................................................................................................................................................ 14-1

Abbreviations ................................................................................................................................................ 14-2
Terminology .................................................................................................................................................. 14-3
15 .......................................................................................................................... 15-1
Intelitek Software Licensing ........................................................................................................................... 15-1

Registration Methods .................................................................................................................................... 15-3
Permanent Licenses ....................................................................................................................................... 15-5
Protect your permanent license ................................................................................................................. 15-5
Transfer a permanent license from one PC (source) to another PC (target).............................................. 15-5
Return a permanent license to Intelitek, so you can retrieve it later ......................................................... 15-5
FAQs Frequently Asked Questions ............................................................................................................ 15-6
User Manual vi OpenCIM

Table of Contents
1
Introduction
This chapter introduces the OpenCIM software and describes the various chapters of this
manual, the information included in each chapter, how to use this manual and so on. It
includes the following sections:
About CIM, introduces general CIM concepts and advantages.
About OpenCIM, introduces Intelitek's OpenCIM software, and
describes the available OpenCIM products.
About This Manual, provides the list of chapters available in this
manual.
Who Should Use This Manual, describes the varied target audience
(such as, students, instructors and administrators).
How to Use This Manual, describes which chapters are intended for
which target audience.
User Manual 1-1 OpenCIM

Introduction
About CIM
To stay competitive, factories are increasingly automating their production lines with
Computer Integrated Manufacturing (CIM) systems. A CIM cell is an automated assembly
line that uses a network of computers to control robots, production machines, and quality
control devices. The CIM cell can be programmed to produce custom parts and products.
CIM provides many advantages:
Computer integration of information gives all departments of a
factory rapid access to the same production data.
Accessibility of production data results in faster response to change,
which in turn shortens lead times, increases the companys
responsiveness to customer demands and competition, and improves
due-date reliability.
Computer aided scheduling optimizes the use of the shop floor. This
improves the utilization of machine tools, and reduces work-in-
progress and lead times.
Real-time production data can be used to optimize the production
processes to improve quality, using techniques such as statistical
process control.
Computer analysis and prediction of material requirements for
production can reduce inventory levels and lead times. Integration
with suppliers and customers can provide even greater benefits.
Downloading machining instructions, including tool changes, from
CAM (computer aided manufacturing) systems to CNC machines
(computer numerically controlled) reduces machine setup times and
increases machine utilization.
The trend among manufacturers today is to produce smaller batches of more varied products.
Without CIM automation, this trend would result in higher costs associated with increased
setup time and additional labor.
There is a shortage of qualified CIM technicians and engineers. Manufacturers demand
graduates who understand the integration of all elements of a CIM. Inteliteks
OpenCIM system addresses this need by providing an industrial-level training system for the
educational environment.

Introduction
About OpenCIM
OpenCIM is a system which teaches students the principles of automated production using
robotics, computers, and CNC machines. It also allows advanced users to search for optimal
production techniques by experimenting with different production techniques.
OpenCIM offers a simulation mode in which different production strategies can be tested
without actually operating the CIM equipment.
OpenCIM provides a realistic, expandable environment through interfaces to third party
hardware (CNC machines, robots, peripheral equipment, etc.). Students can learn first-hand
how other disciplines such as Production Scheduling, Manufacturing Resource Planning
(MRP), Order Entry Systems, and Database Management Systems (Xbase) can be used to
optimize the production process.
In this version of OpenCIM, two additional OpenCIM products are also available:
OpenFMS for a small CIM system which may include a single
robot and one or two CNC machines.
OpenCIM Offline a simulation only version of OpenCIM.

Introduction
About This Manual
This manual is a complete reference guide to the OpenCIM system. It explains how to
install, configure and operate the OpenCIM software. Indications as to which information is
not relevant to the additional OpenCIM products are provided in the appropriate sections.
This manual includes complete details on how to produce custom parts, add your own
computer-controlled equipment, and how to interface with other software.

Introduction
How This Manual is Organized
Chapter 1 Introduction: Provides an introduction to OpenCIM and to this OpenCIM
User Manual.
Chapter 2 System Overview: Describes the hardware and software components
which comprise an OpenCIM cell.
Chapter 3 Safety: Provides the general rules, followed by a brief discussion of the
safety requirements of each component.
Chapter 4 Installation: Describes the hardware assembly process and the software
installation and configuration procedures.
Chapter 5 Project Manager: Describes the Project Manager application that
launches the Virtual CIM Setup and CIM Manager. It enables users to
manage their own projects, and administrators to manage the projects in
the archive.
Chapter 6 Operating CIM Manager: Describes how to operate the CIM Manager
which is used for operating the OpenCIM system and controlling
production.
Chapter 7 CIM Manager Utility Programs: Describes the CIM Utility Programs
which are used for preparing the OpenCIM system for production.
Chapter 8 Virtual CIM Setup: Describes the Virtual CIM Setup aplication which is
an interactive graphic module that enables you to create a simulated CIM
cell.
Chapter 9 OpenCIM Device Drivers: Describes the OpenCIM devices drivers,
which are interface programs that translate and transmit messages between
the CIM Manager and the various machines and controllers at CIM
stations.
Chapter 10 Web Viewer: Describes the Web Viewer application enabling you to
remotely access a specific CIM Manager cell and track the production
cycle.
Chapter 11 OpenCIM Programming: Provides various programming and advanced
OpenCIM features.
Chapter 12 Inside OpenCIM: Describes various OpenCIM administration procedures
for the advanced user, and describes the OpenCIM directory structure.
Chapter 13 Troubleshooting: Describes device error handling, OpenCIM error
messages and more.
Chapter 14 Glossary: Provides the abbreviations and terminology used in OpenCIM
Chapter 15 Intelitek Software Licensing: Describes the various procedures involved
in registering your OpenCIM software.

Introduction
Who Should Use This Manual
This manual is intended to be used by the following:
Students Students can operate the OpenCIM system to gain experience
with computer integrated manufacturing (CIM) or Flexible
Manufacturing Systems (FMS). By working with a complete
CIM system, students are encouraged to think globally
about the manufacturing process. Students can also
concentrate on a particular aspect of a CIM system such as
controlling robots, CNC machines, etc.
Industrial Management OpenCIM allows advanced users to implement and
Students experiment with theories concerning optimal computer
integrated manufacturing techniques such as:
The effect of different machines which can perform
the same process
Modifying a process by changing a machines control
program
Alternate part definitions
OpenCIM can also be used in simulation mode to search for
optimal production strategies by experimenting with the
following:
The causes of production bottlenecks
The effects of alternative production schedules
What-if analyses
For example, OpenCIM can help answer questions such as:
Is it more efficient to do a quality control check at the end of
each operation or just once at the end of the manufacturing
process?
With OpenCIM you can use a simulation mode to easily test
both methods and then observe the results.
Instructors Instructors who want to demonstrate automated production
techniques using the OpenCIM system.
System Administrators System administrators in charge of installing, maintaining,
and troubleshooting the OpenCIM system will want to
become familiar with all aspects of this manual.

Introduction
How to Use This Manual
The OpenCIM software can be operated and used fully without OpenCIM hardware.
Therefore, the emphasis in this manual is placed on the use of the software.
This manual assumes all users are familiar with the following topics:
Safety and basic operating procedures associated with robots, CNC
machines, and all other equipment in the CIM environment.
Basic operation of MS-Windows.
System administrators and advanced users should be familiar with the following topics:
Robotic programming using the ACL language
Robotic programming using Scorbase language
Controlling and operating machines (e.g., CNCs)
RS232 communications
PC LAN administration, operation, and troubleshooting
Setting up programmable logic controllers (PLCs)
Even if you will not be using the software in conjunction with an actual OpenCIM system,
all users should read the background information provided in Chapter 1, Introduction, and
Chapter 2, System Overview and the Safety guidelines in Chapter 3.
The installation instructions provided in Chapter 4, Installation, are intended for instructors
and technical personnel who will be handling software and hardware installation.
Chapter 5, Project Manager, which activates the OpenCIM applications (CIM Manager and
CIM setup), enables you to manage your own projects and provides an archive containing
read-only projects managed by the CIM administrators.
Chapter 6, Operating CIM Manager and Chapter 7, CIM Manager Utility Programs, are
organized to help all users begin using the OpenCIM system as quickly as possible. The
material is presented in the order required to prepare and operate the OpenCIM system and
the procedures guide you through the basic steps of software operation.
Chapter 8, Virtual CIM Setup, presents the Virtual CIM module, and teaches you how to set
up the CIM by means of a graphic editor.
Chapter 9, OpenCIM Device Drivers, describes the operation of OpenCIM device drivers
that are used in OpenCIM.
Chapter 10, Web Viewer, describes how you can remotely access a specific CIM Manager
cell and track the production cycle.
Chapter 11, OpenCIM Programming, enables advanced users to do their own production
experiments beyond the scope of the sample applications in order to explore new CIM
techniques.
Chapter 12, Inside OpenCIM, contains details about the OpenCIM software, files and
directory structure, and provides the information necessary for customizing the OpenCIM
environment.
Chapter 13, Errors and Troubleshooting, provides detailed information on error handling and
troubleshooting.
Chapter 14, Glossary, presents explanations of abbreviations and terminology used in the
OpenCIM system.
Chapter 15, Intelitek Software Licensing, provides full details on the OpenCIM software
licensing process.

Introduction
2
System Overview
This chapter describes the hardware and software components which comprise an OpenCIM
cell. It discusses each component individually and also how all components work together. It
OpenCIM Description, describes the OpenCIM unique features, and
the additional OpenCIM software packages that are provided.
Production Operations, describes the operations performed in the
CIM cell when producing a product and provides an OpenCIM
sample application.
Components of the OpenCIM Cell, describes the basic elements
(hardware and software) of the OpenCIM cell.
Stations, describes the various stations (such as ASRS, Assembly,
QC stations) including their functionality and provides a schematic
example of the OpenCIM cell.
Material Flow in the OpenCIM Cell, describes the basic flow of
parts in a CIM Cell and provides descriptions of the various
components involved in material flow. These may include templates,
pallets, robots and so on.
CIM Control & Optimization, describes how the OpenCIM cell is
controlled and provides descriptions of the elements involved in the
control of the CIM cell. These include the CIM Manager, the station
manager, the graphic display and so on.
Device Drivers, describes the various device drivers in OpenCIM.
These include ACL device driver, CNC machine device driver, PLC
device driver, Scorbase device drivers and so on.
OpenCIM Communication Network, describes the communication
networks that currently exist in OpenCIM. These include LAN,
RS232 and I/O (inputs/outputs).
Integration, provides an example scenario containing a step-by-step
description of the various systems and devices that are associated
with making a product in OpenCIM.

System Overview
OpenCIM Description
This section describes the OpenCIM features as well as the OpenCIM software packages
(such as, OpenFMS, and OpenCIM Offline that are provided in OpenCIM.
Unique Features
This section gives the background for understanding what is special about OpenCIM and
basic operations performed in the OpenCIM system.
OpenCIM software provides unique industrial capabilities not found in other educational
CIMs:
OpenCIM feels familiar to first-time users because it is based on
the standard Windows Graphic user interface.
OpenCIM allows for targeted training at a given station or device.
OpenCIM is realistic because it uses equipment found in actual
industrial CIMs.
OpenCIM resembles industrial CIMs in its ability to grow by using
distributed processing at each production station. Distributed
processing also makes for a more robust system. Even if the PC
performing the central manager function goes down, each machine
can still be operated in a stand-alone mode.
OpenCIM uses a sophisticated network of PCs which allows various
devices to perform multiple operations simultaneously. This network
also allows CIM devices to communicate with each other.
OpenCIM provides you with a powerful, yet flexible report
generator. This utility program allows you to access nine types of
predefined reports or gives you the option of creating your own user-
defined reports.
OpenCIM uses the latest object oriented techniques in:
Defining the CIM Layout: Click on a Graphic object and drag it to
the appropriate location on the CIM layout screen (e.g. Drag a robot
in order to place it beside a CNC machine).
Defining an Objects Properties: Click on an object to set its
properties, e.g. the type of parts a machine can handle.
Graphic Production Tracking: Uses Graphic objects to simulate CIM
operation on screen.
OpenCIM allows you to run a production simulator on a PC to
observe results without actually operating the CIM production line.
OpenCIM provides the opportunity to observe how a set of diverse
hardware components work together in a real-world environment.
OpenCIM is more comprehensive than other limited function CIMs.
It can use a variety of equipment including:
A variety of robots
Processing machines
Quality control devices (machine vision, laser scan meter, height
gauge, CMM, caliper)
Automated storage and retrieval systems (ASRS)
Peripheral devices (barcode scanner, X-Y table, electric screwdriver,
laser engraver, etc.)

System Overview
Custom devices by allowing you to easily set up your own device
interfaces
OpenCIM offers Graphic production tracking allowing you to
observe each production operation on a central display.
OpenCIM provides an open environment for advanced users who
want to:
Add their own devices
Design their own products
Interface their own software (e.g. MRP and cost analysis)
Analyze CIM production data
OpenCIM is a robust system that enables recovery from errors
without the need to reset the entire CIM cell.
OpenCIM Additional Software Packages

The additional OpenCIM software packages, OpenFMS, OpenCIM Offline that are provided,
are each described in detail in the following sections.
OpenFMS
OpenFMS is designed for use with flexible manufacturing systems. OpenFMS includes all
the software modules and features of OpenCIM, and is intended to support systems with one
robot tending one or two machines and quality control devices.
The following items are not included in the Virtual FMS Setup module, nor can they be
configured for online operation.
Included in OpenFMS Not included in OpenFMS
All types of robots
Slidebases, linear conveyors, XY and linear Closed loop conveyor
positioning tables
ASRS-36 and all smaller storage device and ASRS2 and ASRS carousel
part feeders
All CNC machines Laser engraver
ViewFlex machine vision system, electronic Coordinate measuring machine, electronic
calipers, laser scan meter height gauge, barcode reader
Automatic gluing application; Hydraulic robot and pressing station;
Automatic screw driving application Pneumatic part feeding/sorting station;
Process control station
OpenCIM Offline
OpenCIM Offline is the simulation version of OpenCIM. The user can design and run an
unlimited variety of CIM or FMS cells in simulation mode.
It does not support hardware or online operation.
Device drivers are not included in this package.

System Overview
Production Operations
The following operations are performed in the CIM cell when producing a product:
Supplied parts (raw materials) are loaded into storage locations.
Manufacturing orders are generated by the CIM Manager or by an
external production scheduling package such as Fourth Shift or
MAPICS.
Parts are removed from the ASRS and transported on the conveyor to
production stations.
Robots take parts from the conveyor and move them to various
production machines (e.g. CNC machines) at a station (machine
tending).
Typical production tasks include:
Processing in a CNC machine
Assembling two or more parts
Quality control tests
Robots return processed parts to the conveyor for transportation to
the next station.
Finished products are removed (unloaded) from the cell.
OpenCIM Sample Application - The Covered Box

The following Covered Box sample application is used in this manual to demonstrate the
concepts of the OpenCIM system and can be found in the TUTORIAL_SAMPLE provided
in the archive project list. The steps shown below are explained in more detail as each topic
is introduced later in this manual.
The sample application produces a simple, covered box from a small, solid cube and a
matching cover. Each component part is assumed to be in place on a separate template in the
ASRS.
Figure 2-1: Part Definition Tree for Sample Application

The following steps detail the process of making a covered box:
1. The ASRS robot takes a solid cube and a cover from a storage cell and places them on
separate pallets on the conveyor.
2. When the cover arrives at the assembly station, the assembly robot places it in a rack
until the matching box arrives.
3. When the cube arrives at a CNC station, the CNC robot places the cube into a milling
machine. The CNC machine reams out the center of the cube to form a box.
4. The CNC robot places the box on the conveyor.
5. When the box arrives at the assembly station, the robot places it on a rack.. When all the
parts required for the assembly are on their rack, the robot places the base part (box) on
the jig. The robot then retrieves the matching cover from the rack and places it on the
box. The robot places the covered box on the conveyor.

System Overview
6. When the covered box arrives at the ASRS, the robot places the finished product in a
storage cell.

System Overview
Components of the OpenCIM Cell
This section describes the elements of the OpenCIM cell. The topics covered include the
physical configuration of the cell, material flow, control and production devices and
communication networks. The emphasis is on the role each component plays in the
integrated system, rather than on providing a detailed description of the component. Later
chapters cover OpenCIM software in greater detail. Consult the appropriate users manuals
for details about each hardware component.
CIM cells are composed of the following basic elements:
Component Description
Conveyor Device that transports parts from station to station.
Production (Work) Locations around the cell where parts are processed and stored
Stations by machines and robots. Robots move parts between the
conveyor and station machines.
CIM Manager The PC that contains the CIM Manager software which
coordinates the functioning of all devices in the cell using a
LAN.
Station Manager A PC that controls the different devices at a station and has a
communication link with the CIM Manager. Device control is
performed by OpenCIM device drivers that run on this PC. A
device driver controls the operation of a device at the station in
response to commands from the CIM Manager and other CIM
elements.
Other Software Tools OpenCIM Modules: Virtual CIM Setup, CIM Manager (with
integrated Part Definition, Machine Definition, Storage
Definition, MRP, Scheduler-Gantt, Reporter, Graphic Tracking
modules), Project Manager, Performance, Optimization and
Web Viewer.
Third Party Software: Other production related software that
interfaces to OpenCIM such as Production Scheduling,
Manufacturing Resource Planning (MRP and MRP-II), Order
Entry Systems, Data Base Management Systems (Xbase), etc.
Typically, a separate PC is dedicated to running or controlling each of the above elements.
While two or more functions can be combined on a PC, the following discussion assumes the
use of dedicated PCs.

System Overview
Stations
The OpenCIM cell is composed of a set of stations located around a conveyor as shown
schematically in the figure below:
Figure 2-2: Schematic Example of an OpenCIM Cell

Each station is controlled by a Station Manager PC. A CIM Manager PC coordinates the
activities of all stations. The number of stations may vary from cell to cell. A typical
educational OpenCIM cell ranges from up to eight stations arranged around one conveyor to
as few as a single station consisting of a robot tending a machine. The software can be
adapted to more stations and conveyors.
Production commands are sent from the CIM Manager computer to the device drivers via the
Station Manager PC. Status messages generated by devices are interpreted by the device
driver and sent back to the CIM Manager.
Just as each industrial cell is an individual application of CIM technology, every OpenCIM
cell has its own configuration. Generally, the stations that are usually available are described
in the following table:
Station Description
ASRS Station Automated Storage and Retrieval System. Automatic warehouse
which supplies raw materials to the OpenCIM cell, stores parts in
intermediate stages of production, and holds finished products.
Machine Station Station where materials are shaped, formed, or otherwise
processed (e.g. using a CNC machine or laser engraver).
Assembly Station A station where parts are put together. The resulting new part is
called an assembly. Peripheral equipment and devices at an
Assembly Station include an automatic screwdriver, Welder, X-Y
table, part feeders, various robot grippers, etc.
QC Station Quality Control. Inspection of parts using machine vision, laser
scan meter, height gauge, continuity tester, CMM, caliper or other
QC machines.

System Overview
Various functions may be combined at one station, such as quality control and assembly.
Stations contain devices that perform production activities such as material processing or
inspection. The following elements are generally present at a station:
Element Description
Robot A device which moves parts around a station (e.g. inserts parts
into a CNC machine) and/or performs assembly operations.
Robot Controller For example, an ACL controller which controls the robot and
certain optional peripheral devices (e.g. X-Y table, barcode
scanner).
Station Manager PC A Station Manager PC where the device drivers are located
that:
Translate OpenCIM production messages and
commands to/from each station device (e.g. the ACL
controller).
Provide a user interface for controlling station devices
by manually sending OpenCIM commands (e.g. to
CNC machines or an ACL controller).
Function as a terminal for devices that use an RS232
interface for setup and programming (such as the ACL
controller).
Machine A device that processes parts at a station. CNC machines such
as lathes and mills process parts according to user-supplied G-
code programs.
Robot Peripheral A peripheral device which aids the robot in material handling
tasks (e.g. a linear slidebase that supports a robot, an X-Y
table, a tool adapter, various grippers such as pneumatic or
suction models, etc.).
An example of an OpenCIM cell is shown schematically in the following figure:
Figure 2-3: Sample OpenCIM Cell

System Overview
Material Flow in the OpenCIM Cell
Material handling tasks can be divided into two groups:
Primary Material Handling: These tasks perform the transportation
of parts between stations.
Secondary Material Handling: These tasks perform the handling of
parts within a station, such as placing a template on the conveyor,
removing a part from a feeder, inserting a part in a CNC machine,
assembling parts and so on.
In an OpenCIM cell, the primary material handling tasks are usually performed by the
conveyor. A robot (in combination with its peripherals) performs the secondary material
handling tasks at each station.
When a robot removes a template from the conveyor, it typically places it on a buffer. (A
buffer is a tray designed to hold a template when it is removed from the conveyor. The
standard buffer is attached to the outer rim of the conveyor.) Once the template is on the
buffer, the robot can remove a part from the template and take it to a station device.
The following scenario describes the basic flow of parts within the CIM cell:
In response to production orders, the CIM Manager issues
instructions to release parts from the ASRS and move them from
station to station for processing.
A robot at each station takes parts from the conveyor and places them
in station machines.
After a part has been processed at the station, the robot places the
part back on the conveyor where it moves to the next station
according to its production plan.
Templates
Templates are plastic trays which can hold various types of parts. They allow parts to be
transported on the conveyor.
Figure 2-4: An Empty Template

A template contains a matrix of holes in which pins are placed to fit the dimensions of a part.
Each arrangement of pins defines a unique template type. Each part may only be held by its
assigned template. The handle, located on top of or in front of the template, facilitates
grasping by a robots gripper.
An optional barcode sticker on the side of the template shows the templates ID code. When
barcodes are used, a barcode reader can verify the identity of each template inserted or
removed from the ASRS.

System Overview
Storage
An ASRS station is typically used as the main source of raw material for the cell. The ASRS
can also serve as a warehouse for parts in various stages of production. Storage cells in the
ASRS contain templates, either empty or loaded with parts. A CIM cell may contain any
number of ASRS stations.
Part feeders can also be used to supply raw materials at various stations around the cell.
The following ASRS models exist in OpenCIM:
2 2
ASRS : The ASRS model is specifically designed to work in the
OpenCIM environment. This unit contains a dedicated cartesian
robot with an additional rotary axis that moves between two sets of
storage racks. Each rack has a set of shelves divided into storage cells
that are designed to hold part templates. The robot, which is
controlled by a standard ACL Controller-B, moves templates
between the conveyor and storage cells.
Figure 2-5: The ASRS2 Robotic Storage Station

ASRS Carousel: The ASRS carousel is a three-tier rotating
warehouse which is tended by a robot, and controlled by an ACL
controller.
ASRS-36: The ASRS-36 is a cartesian robot with an additional rotary
axis. It has a set of storage racks (divided into six levels with six cells
each). The robot, which is controlled by a standard ACL Controller-
A, moves the parts between the shelves and the conveyor.
ASRS-36u,ASRS-36uX2: The ASRS36u and ASRS-36uX2 are
cartesian robots with additional rotary axes. They each have a set of
storage racks (divided into six levels with six cells each). The robots,
which are controlled by USB controllers, move the parts between the
shelves and the conveyor.
ASRS Rack: The ASRS rack has a small number of cells, and is
designed for use in a Micro-CIM work cell.

System Overview
Conveyor and Pallets
A pallet is a tray which travels on the CIM conveyor and is designed to carry a template. To
transport a part to another station, a robot places the template carrying the part on a pallet on
the conveyor. The OpenCIM conveyor carries pallets in a continuous circuit from station to
station. The conveyor is controlled by a PLC (programmable logic controller).
Each pallet has an ID number which is magnetically encoded in a bar on the pallet. In normal
cell operation, each pallet is stopped briefly when it arrives at a station so that its magnetic
code can be read. If the PLC determines that the pallet is needed at this station, it informs the
CIM Manager. The pallet remains at this station until the CIM Manager sends a release
command. While a pallet is stopped, the conveyor continues to transport other pallets which
are moving between stations.
The location at which a pallet is stopped is called a conveyor station. Each OpenCIM station
has its own conveyor station, which contains two pneumatically operated pallet stops, a
magnetic pallet-arrival sensor, a magnetic pallet-in-place sensor and a set of magnetic pallet-
code sensors.
Figure 2-6: Pallet at Conveyor Station

Piston stops at each conveyor station can be raised to hold a pallet in place while the
conveyor continues to cycle past the stations. The PLC controls the operation of these
pneumatically driven piston stops, using input from pallet detection sensors located at the
conveyor station.
The PLC keeps track of pallets which are empty and those which are carrying parts. It sends
the destination station of each pallet to the PLC (default destination for each pallet is #99,
allowing the pallet to continuously circle on the conveyor). Magnetic code readers at each
station enable the PLC to identify the pallet ID numbers. Through a look-up-table the CIM
Manager can instruct the PLC to do the following:
If ... Then the PLC stops the pallet if ...
Pallet is empty A template containing a part is ready to be picked up at this
station.
Pallet carries an empty A part with no template needs to be picked up at this station.
template
Pallet carries a template This part needs to be delivered to this station.
with a part
If the part carried by the pallet does not require processing at the station, the pallet is allowed
to continue on the conveyor.
Even though a pallet may be needed at a station, the CIM Manager may direct the PLC to
release it if the robot that handles templates at this station is busy. Otherwise, a bottleneck
could occur on the conveyor since other pallets would not be able to pass until the robot
becomes available. The PLC would then stop the next appropriate pallet and try again.
If the robot is free it is instructed to remove the template containing the part from the pallet
and place it on a station buffer. The empty pallet is then released and can continue on the
conveyor, ready to pick up another template.

System Overview
Conveyor Lights
Red and green lights at each conveyor station indicate the following:
Option Description
Green On Station is idle waiting for a pallet to arrive.
Red On A pallet has been stopped for use at this station.
Flashing Red An error has been reported at this station by an OpenCIM
device driver (e.g. robot impact, Emergency button pressed).
Flashing Red at All Stations All stations have stopped because someone has pressed the
Emergency Stop Button.
Robots and Controllers

CIM robots move parts within a station (secondary material handling) and perform assembly
operations. Robots vary in speed, payload, accuracy, range of movements (degrees of
freedom), working envelope (horizontally or vertically articulated), and drive mechanism
(DC servo, AC servo or pneumatic).
The following Intelitek robots may be integrated in an OpenCIM environment:
Robots controlled by Scorbase:
SCORBOT-ER 4u
ASRS-36u
ASRS-36uX2
SCORBOT-ER 9Pro
SCORA-ER 14Pro
HP3 with NXC100 and XtraDrive controllers
Robots controlled by ACL:
SCORBOT-ER 5, SCORBOT-ER 5 Plus
SCORBOT-ER 7
SCORBOT-ER 9
SCORA-ER 14
PERFORMER-MK3
Performer-SV3 with BRC controller
MK2
Square ASRS

System Overview
Figure 2-7: Robot, Controller, Teach Pendant, and Station Manager PC
Intelitek robots may be operated using either ACL or Scorbase as their programming
language. Each programming language uses a device driver in order to communicate with
the OpenCIM manager software.
Robotic programs inform the robot what path to follow and what task to perform once it
reaches a destination. The controller (ACL, USB or USB PRO) provides the power supply to
the robot and moves the robot by controlling the power to the motors inside the robot.
The controller can control robots and peripheral devices (e.g. barcode reader, X-Y table)
simultaneously. The CIM peripheral devices are connected to the controllers auxiliary
I/O ports and RS232 ports. All ports (robot, I/O, RS232) can be controlled using Robotic
programs.
Processing Machines
Processing machines process parts according to processing programs stored in their memory.
The CIM Manager keeps track of the programs that reside in a machines memory and
downloads a new program to process an upcoming part as needed.
OpenCIM can interface to machines that use either I/O lines or an RS232 interface to control
operations such as opening/closing a door, turning on/off the machine, etc. Status lines report
information, such as whether a door is open or closed and when a process is finished.

System Overview
CIM Control & Optimization
To understand how the OpenCIM cell is controlled, it is necessary to look at its control
elements, the communication channels that each element uses to control the devices, and the
network that links the various control elements as an integrated whole.
The OpenCIM system consists of various software modules which perform command,
control, and monitoring functions:
Virtual CIM Setup Software
CIM Manager Software with integrated modules (Storage Definition,
Machine Definition, Part Definition, MRP, etc.)
Device Managers (device drivers located on Station PC)
Conveyor Manager (PLC device driver located on a Station PC)
Graphic Tracking (integrated in CIM Manager and/or as external
module)
OpenCIM uses a distributed control strategy as follows:
Each Station Manager PC runs a set of device drivers that control the
devices at its station.
A PLC controls the operation of the conveyor.
The CIM Manager provides the highest level of control and
integrates the activities of the entire cell. It sends command messages
to the various device drivers via the network. These units attempt to
execute the command and respond with status messages describing
the results.
What is Optimization?
In multiple productions (when producing more than one part in a manufacturing cycle) it is
required to optimize the timing synchronization to maximize system functionality at
minimum costs. This process is called System Optimization.
There are two types of system optimization methods. In the first method, the schedule is
defined in advance and a detailed schedule is set for each machine. In the second method, a
set of rules is defined, according to which the system acts, and during run-time, decisions are
made according to this set of rules. The Optimization Approach used by OpenCIM
implements this second method which enables the system to overcome failures, imprecision
and inaccurate assumptions, and still provide you with an efficient system.
In a CIM system, the Time, Cost and Quality factors determine the efficiency of the overall
system performance. These factors are the target functions of the different algorithms (or of
the system). Generally, combinations of these three factors are used in a CIM manufacturing
cycle. Additional factors, such as the machine type, can also affect the performance of the
CIM cell.
The CIM Manager controls the efficiency of a manufacturing cycle, by performing the
following tasks:
Scheduling: The CIM Manager determines the time schedule that a
part will be released from storage and in what order.
Dispatching: The CIM Manager determines which part will be
processed in which machine and when.
These Scheduling and Dispatching tasks are controlled by the CIM Optimization Definition,
as described in Optimization in Chapter 7, CIM Manager Utility Programs.

System Overview
CIM Definition Modules
The CIM Manager maintains the OpenCIM database which contains information on the
physical and communication configuration of the cell, inventory of raw materials and parts,
manufacturing processes, part definitions, and orders. Interactive software lets you define:
The layout of machines and stations in the CIM cell.
Machines and the production processes they can perform
The bill of materials used to produce each part.
An order which specifies the parts you want to produce.
The contents of all storage locations.
The CIM Definition modules also allow you to back up and restore the above information.
The CIM Definition modules are usually run on the same PC used for the CIM Manager.
Each of these modules creates data files in a DBF format. These files can be viewed and
edited with a dBASE editor or with the DataBase Tool which can be activated from the
Manager software (for details refer to Chapter 6: Operating CIM Manager). They can also be
modified by a user-supplied application (e.g. using an MRP program to create an order file).
The CIM Manager

The CIM Manager performs the following basic functions:
Evaluates the Production Plan: Fills in details in the production
plan on how to produce the parts submitted in an order.
Executes the Production Plan: Controls and monitors the CIM
equipment to produce the parts as specified in the production plan.
The CIM Manager program provides centralized control of on-line production activities. It
sends commands to station devices and receives responses which enable it to track the flow
of parts during production.
After the production plan has been prepared, you can issue commands to start and stop
production from the CIM Manager. When you start production, the CIM Manager begins
sending commands over the LAN to Station Manager PCs in order to:
Direct the flow of parts between stations on the conveyor.
Gather at a station (e.g. in a storage rack) the parts that are needed in
order to perform an assembly operation.
Synchronize processes which can be performed concurrently and
those which must be performed consecutively.
The CIM Manager runs a virtual machine that corresponds to each physical machine in the
CIM. This virtual machine keeps track of the status and parts queue at the physical machine.
The CIM Manager uses this information to decide when to send routing messages to bring
parts to the machine.
The Station Manager

A Station Manager PC can be connected to a variety of robots and machines. It runs a
separate device driver in order to communicate with the controller for each device connected
to this PC. These device drivers run simultaneously in individual windows using the
multitasking capabilities of MS-Windows. A PC running a set of OpenCIM device drivers is
said to be acting as a station manager. These OpenCIM device drivers perform the following
functions:

System Overview
Translate OpenCIM commands into instructions understood by
station devices.
Translate status information from a device into OpenCIM messages
and relay these messages to the appropriate OpenCIM entities.
Allow the user to interactively control devices such as CNC
machines, robots, and other station devices.
Download G-code programs to a CNC machine.
If desired, the station computer can be used to operate the station as a stand-alone
manufacturing cell. Each device driver on a station PC has a control panel which provides
this capability.
PC Requirements in OpenCIM
The OpenCIM system provides great flexibility in the way in which PCs are used around the
cell. You can control the degree of distributed processing in the OpenCIM environment
based on how you assign the following software modules to PCs:
CIM Manager
Device Manager (i.e. OpenCIM device drivers)
Graphic Tracking
In a busy CIM cell, performance is enhanced by installing most of the above software
modules on a separate PC. In this scenario, each station would have a dedicated Station
Manager PC. A LAN is used to connect all of the PCs that are running OpenCIM software.
The OpenCIM software modules use this LAN to exchange information.
At the other extreme, all of the above OpenCIM software modules could be loaded on one
high-performance PC. Multiple OpenCIM software modules can run on the same PC in the
multi-tasking environment provided by Windows. In this case, inter-module communication
is internal, where services are provided by the operating system. When a single PC is used,
no LAN is required, although Network Settings for the PC still have to be configured for
TCP/IP.
Intermediate configurations are also possible. For example, one PC may be used to run both
the CIM Manager module as well as the PLC device driver. A single Station Manager PC
may be connected to devices at different stations.
Figure 2-8: OpenCIM Modules Distributed Among PC's

System Overview
Figure 2-9: OpenCIM Modules Concentrated in One PC
Recommended PC requirements for OpenCIM software are:

Pentium 4 Dual Core with 3 GHz processor or higher
At least 512 MB RAM (2 GB for Windows Vista/7)
CD ROM drive
Windows XP/Vista/7 (32/64 bit)
Hard drive with at least 1 GB of free disk space
Super VGA or better graphics display, minimum 256 colors
Fully Windows compatible LAN interface card
USB port
Separate RS232 ports on the PC-for each hardware device which uses
an RS232 port
Mouse or other pointing device
Minimum PC requirements are:

Pentium 4 Dual Core with 2 GHz processor
512 MB RAM
CD ROM drive
Windows XP Professional (32/64 bit)
Hard drive with at least 1 GB of free disk space
Super VGA or better graphics display, minimum 256 colors
Fully Windows compatible LAN interface card
USB port
Separate RS232 ports on the PC for each hardware device which uses
an RS232 port
Supported Windows version (32/64 bit):

Windows XP Professional
Note
Windows Vista Home Premium/Business/Ultimate
Windows 7 Home Premium/Enterprise/Professional/Ultimate

System Overview
If a PC is used for multiple functions, the PC must be powerful enough to keep up with the
flow of information in the OpenCIM real-time environment. For example, a very high
Note
performance PC would be required to simultaneously run the CIM Manager program,
control the conveyor, function as a Station Manager, and show the Graphic production
display in real-time.

System Overview
Device Drivers
Each device at a station is controlled by an OpenCIM device driver program running on the
Station Manager PC. A device driver translates OpenCIM messages in two directions:
OpenCIM instruction messages into a set of commands understood
by the target device.
A response from the device into an OpenCIM status message.
After a device driver translates an instruction into a command, it sends the command to the
destination machine or robot.
OpenCIM instructions can come from:
The CIM Manager
Other OpenCIM device drivers
The device drivers user interface
User application programs
When a device returns a response, the device driver translates this information into a
standard OpenCIM message format. It then relays this information as follows:
Device status information to the CIM Manager.
Real-time production data to the Graphic Tracking module.
Designated messages from a device to a user defined process that is
monitoring this device.
Specific messages to other device drivers.
A separate copy of a device driver is run on a Station Manager PC for each device at the
station. Each device driver presents a control panel which allows you to:
Observe the command and response messages on-screen as they are
sent to and from a device.
Issue commands interactively to a device and observe its responses
on-screen.
Capture all commands and responses in a log file if you want to
analyze the behavior of a device.
Parameters which control the operation of each device driver are found in the device drivers
configuration files (ACLVD1.INI, CNCVD1.INI). You can view and change these
parameters by editing this file with a text editor.

System Overview
Robotic Device Drivers
The robotic device driver communicates with a robotic controller, which controls robots
(including the ASRS). This robotic device driver receives command messages from the CIM
Manager to perform robotic operations. The robotic device driver then translates these
requests into commands to run the corresponding robotic programs residing in the robotic
controller. When the controller has finished moving the robot, it sends a confirmation
message back to the device driver which forwards it to the CIM Manager.
The following robotic device drivers are used in CIM:
ACL Device Driver: The ACL device driver uses an RS232 port on
the Station Manager PC to communicate with the ACL controller.
Scorbase for Controller USB Device Driver: The Scorbase
software operates the Controller USB, using the Scorbase device
driver (residing in the software).
Scorbase for Controller USB-Pro Device Driver: The Scorbase for
Controller USB-Pro software operates the Controller USB-Pro, using
the Scorbase device driver (residing in the software).
Scorbase for NXC 100 and XtraDrive Controllers Device Driver:
The Scorbase for NXC100 and XtraDrive Controllers software
operates the NXC100 and XtraDrive Controllers, using the Scorbase
for NXC100 and XtraDrive Controllers device driver (residing in the
software).
Scorbase for FS100 and XtraDrive Controllers Device Driver:
The Scorbase for FS100 and XtraDrive Controllers software operates
the FS100 and XtraDrive Controllers, using the Scorbase for FS100
and XtraDrive Controllers device driver (residing in the software).
The primary operation performed by a robot using pick-and-place. Pick-and-place means,
taking a part from one location (source) and placing it at another location (target). For
example, a common pick-and-place operation involves taking a part from a template and
placing it in a CNC machine. The coordinates for each pick-and-place operation are defined
in advance and assigned a Location ID. The CIM Manager sends a pick-and-place command
to the controller which includes two Location IDs (source and target).
The actual path a robot follows when moving from a source location to a target is defined in
a robotic program residing in the robotic controller. The CIM is not involved with the
complexities of robot movement. It only sends pick-and-place commands which specify the
action to take, not how to take it.
In specific CIM station configurations, the robotic controller also controls the various
devices (such as, barcode readers and CNC machines). In some cases, the communication
between the CIM Manager and these devices is handled via the robotic device drivers by
activating a robotic program that is responsible for communicating with the device. This is
performed according to the ACL or USB configuration, as follows:
ACL Configuration: The RS232 from the peripheral device (such
as, CNC or barcode reader), is connected to the ACL controller and is
controlled by an ACL program. The ACL device driver then activates
this program to operate the device. For example, write specific code
into the RS232 line that is connected to the device.
Scorbase for Controller USB: The RS232 from the peripheral
device (such as, CNC or barcode reader), is connected to the PC
COM port and is controlled by the Scorbase program. The Scorbase
device driver then activates the appropriate sub-routine to activate the
device. For example, write specific code into the RS232 line that is
connected to the device.

System Overview
Scorbase for Controller USB PRO: The RS232 from the peripheral
device (such as CNC or barcode reader), is connected to the PC
COM port and is controlled by the Scorbase for USB-PRO controller
program. The Scorbase for USB-PRO controller device driver then
activates the appropriate sub-routine to activate the device. For
example, write specific code into the RS232 line that is connected to
the device.
Scorbase for NXC100: The RS232 from the peripheral device (such
as CNC or barcode reader), is connected to the PC COM port and is
controlled by the Scorbase for NXC 100 and XtraDrive controller
program. The Scorbase for NXC100 and XtraDrive controllers
device driver then activates the appropriate sub-routine to activate the
device. For example, write specific code into the RS232 line that is
connected to the device.
Scorbase for FS100: The RS232/TCP/IP from the peripheral device
is connected to the PC (COM port or LAN port) and is controlled by
the Scorbase for FS100 and XtraDrive controller program. The
Scorbase for FS100 and XtraDrive controllers device driver then
activates the appropriate sub-routine to activate the device. For
example, send/receive specific commands through the RS232/LAN
line that is connected to the device.
CNC Machine Device Driver

OpenCIM uses a CNC device driver to interface with any CNC machine that uses I/O lines
or an RS232 interface to receive commands and report machine status. This device driver
can be adapted to work with any such CNC machine using a built-in language to write short
interface routines. The CNC device driver can control a machine, read the status of a
machine, send status messages to other CIM entities, and download G-code programs to the
machine using an RS232 interface.
The normal sequence of events is:
The CIM Manager instructs the robot to load a part into the CNC
machine.
The CNC device driver receives a command to process a part.
The device driver activates the appropriate output line to turn on the
machine.
The device driver waits for the operation to complete by monitoring a
status line.
The device driver sends a status message back to the CIM Manager.
The CIM Manager instructs the robot to remove the part in the CNC
machine.

System Overview
The following sample scenario demonstrates the role of the CNC device driver:
1. The CIM Manager sends a command to the CNC device driver to download a G-code
file needed to machine an upcoming part.
2. When a robot is ready to insert a part into the CNC machine, its Scorbase or ACL
program sends commands to the CNC machine to:
Open the door of the CNC machine
Open the chuck/vice of the CNC machine
3. The robot inserts the part into the chuck/vice. The Scorbase or ACL program sends
commands to the CNC machine to:
Close the chuck/vice of the CNC machine
Close the door of the CNC machine
4. The CIM Manager waits for status lines to indicate that the part is in place ready to be
machined.
5. The CIM Manager sends a signal to the CNC machine (via the CNC device driver) to
begin machining the part.
6. The CNC device driver waits for a status line to indicate that the machining operation is
complete.
7. The CNC device driver sends an Operation Complete status message to the CIM
Manager. The Manager in turn sends a command to the ACL controller to signal the
robot that it can now remove the part from the CNC machine.
8. The Scorbase or ACL program sends commands to the CNC device driver to:
Open the chuck
Open the door
9. The Scorbase or ACL program directs the robot to remove the part. It then sends a status
message to the CIM Manager signaling that the unloading is finished.
The CNC device driver can communicate with a machine using either an RS232 interface or
a special I/O board in the Station Manager PC. For an I/O interface, each status line and
command line for a machine is connected to this board.
In most cases the CNC device driver uses the ACL device driver or Scorbase device driver to
communicate with the machine on RS232 and I/O level.
Since CNC machines from different manufacturers have different sets of status lines and
command lines, the CNC device driver uses a flexible control language called the CNC
Language Interpreter (CLINT) for interacting with the machine. This language allows you to
adapt the device driver to the features and wiring configuration of a specific machine by
writing a set of customized routines. When a part arrives at a CNC machine, the CNC device
driver receives a command to run the corresponding CLINT routine to process this part.

System Overview
PLC Device Driver
The PLC device driver communicates with the programmable logic controller which directs
the operation of the conveyor. This device driver receives messages from the CIM Manager
about the contents and destination of the pallets traveling on the conveyor. The PLC device
driver translates these messages into commands understood by the PLC.
When the PLC detects a pallet arriving or leaving a station, it sends a status message to the
PLC device driver on a station PC. This device driver in turn translates the message into a
standard OpenCIM format. It then broadcasts the message to the CIM Manager, the Graphic
Tracking module, and any user applications which have registered for this type of message.
The control panel of the PLC device driver lists the destination of each pallet and can show
which pallet is at each station. It also lets you interactively issue commands to stop a pallet at
a station.
The PLC is normally connected to one of the Station Manager PCs (using an RS232
connection). This PC communicates with the CIM Manager PC using the LAN.
OpenCIM can accommodate any type of PLC. If a PLC cannot support the pallet look-up
table in its memory, this information is stored on the PLC Manager PC. However, better
performance results when the look-up table is stored in the PLC. This arrangement
eliminates the serial communication overhead associated with performing frequent look-ups
every time a pallet passes a station.
Quality Control Device Drivers

OpenCIM uses a set of device drivers to communicate with different types of quality control
devices such as:
Vision Systems (Viewflex, ROBOTVISIONpro)
Coordinate Measuring Machine (CMM)
Laser scan meters, calipers
Barcode Readers (BCR)
RFID Readers (RFIDR)
These device drivers receive instructions from the CIM Manager to perform a predefined
quality control check on a part. These instructions specify the type of test to perform and the
range of acceptable results. The quality control tests for each part are defined according to
the instructions for each quality control device.
A quality control device driver translates OpenCIM messages into commands understood by
its associated quality control device. The device driver can communicate with quality control
devices attached to either a Station Manager PC or ACL controller via an RS232 interface or
I/O port. When the quality control device performs a test, it sends the result back to the
quality control device driver on the Station Manager PC. The device driver translates the
message into a standard OpenCIM format. It then sends this status message to the CIM
Manager.
The control panel of each quality control device driver lets you observe the results of each
quality control test. It also allows you to interactively issue commands to a quality control
device or send status messages to the CIM Manager.

System Overview
Hydraulic Workstation Device Drivers
The hydraulic workstation device driver communicates with the hydraulic workstation via
Advantechs I/O PCI card. This device driver receives command messages from the CIM
Manager to perform robot operations and activates the press. The hydraulic device driver
translates these requests into commands to run the corresponding programs residing in the
HYD-2800 program on the PC. When the device driver has finished moving the robot, it
sends a confirmation message back to the CIM Manager.
The hydraulic workstation device driver can also activate user-supplied programs that can be
prepared using the HYD-2800 program. These programs are commonly used to control the
hydraulic robot and the press.
Pneumatic WorkStation Device Drivers

The pneumatic device driver runs on a PC that controls the pneumatic station via the Vuniq
software. The pneumatic station is used to supply three types of raw materials. These include
two types of cylindrical parts as well as block parts.
This device driver receives command messages from the CIM Manager to supply raw
material parts to the CIM system. The pneumatic device driver translates these requests into
commands for the manipulator control to perform the following tasks:
Lift the template off the conveyer and place it on the pneumatic
station.
Take the required part from the feeder and place it on the template.
Lift the template and part off the pneumatic station and place it back
on the conveyer.
When the device driver has finished supplying the part, it sends a confirmation message back
to the CIM Manager.
Process Workstation Device Drivers

The process device driver runs on a PC that controls the process station via the Vuniq
software. The process station is used to perform a specified chemical process on raw material
parts. This device driver receives command messages from the CIM Manager to process the
raw material part. The process device driver translates these requests into commands for the
manipulator and process control to perform the following tasks:
Lift the template and raw material off the conveyer and place it on
the buffer.
Lift the raw material off the template and perfom the process,
specified in the Vuniq software. At the end of this process the
processed part is placed back on the template.
Lift the template and the processed part off the buffer and place it
back on the conveyer.
When the device driver has completed these tasks, it sends a confirmation message back to
the CIM Manager.

System Overview
OpenCIM Communication Network
This section describes in detail each of the following communication networks: I/O, RS232,
and LAN.
Figure 2-10: Communication Networks Used in OpenCIM

System Overview
LAN
The CIM Manager and device drivers exchange command and status messages via the
OpenCIM Network. This network is based on the Windows TCP/IP communication
protocol. Each module (manager, device drivers) in the TCP/IP protocol has two
communication sockets, the server and the client. A socket represents an endpoint for
communication between processes across a network. Both the server and the client have an
IP address and a port number that are unique. The OpenCIM Network transparently delivers
the message to the destination application whether it is running on the same PC or on a PC
connected via a LAN.
OpenCIM uses a LAN to exchange information between software modules running on
separate computers. When the following software modules are configured to run on separate
PCs, the LAN allows them to exchange commands and status information in real-time:
The CIM Manager software
The Device Driver software
The Graphic Tracking PC
Any PCs running user supplied applications that are interfaced to
OpenCIM
OpenCIM uses the LAN to:
Send commands from the CIM Manager to Device Drivers (e.g. data
such as part ID #, task to perform, machine to use, etc.)
Send real-time production status messages from Device Drivers to
the CIM Manager.
Allow Device Drivers to retrieve control programs (e.g. G-code)
stored on the server.
Send real-time production status messages to the Graphic Tracking
software.
Transfer CIM messages between different device drivers.
Transfer CIM messages between devices and a user application
running on a networked PC.
Perform central backup and restore of all PCs attached to the LAN.
OpenCIM can use any LAN using a TCP/IP protocol which is supported by Windows to
transfer files and send real-time messages.

System Overview
RS232
An RS232 interface (also known as a serial port or com port on a PC) is a low-speed data
communications port that typically transmits and receives information at the rate of 300-
19,200 bits per second (bps). Data is transmitted serially, i.e. one bit at a time. There is a
separate line for transmitting and receiving data.
The following OpenCIM devices use RS232 connections:
Station Station Manager PCs use RS232 to:
Manager PCs
Download programs to processing machines
Pass OpenCIM messages to/from an ACL controller
Provide a terminal interface for programming ACL controllers
Pass OpenCIM messages to/from other station devices such as
QC systems.
PLC The PLC Manager PC uses RS232 to:
Send pallet destination information to the PLC
Send commands to the PLC
Receive status messages from the PLC
Peripheral Peripheral devices can be attached to the RS232 ports of an ACL
Devices controller (e.g. barcode reader).
Inputs/Outputs
I/O connections can be used to turn production devices on and off, and to transmit binary
information about the status of a device. A separate wire carries each I/O signal. I/O
connections use a low voltage DC signal. The exact voltage depends on the specifications of
the devices being connected.
I/O connections are used for signaling purposes only. An output signal should never be used
to directly drive a piece of electrical equipment. In this case, an output signal should be
buffered through a relay or other device to prevent overloading the circuit.
The following CIM devices use I/O connections:
PLC (to raise and lower piston stops)
Magnetic sensors at conveyor stations used to send pallet IDs to the
PLC
Processing machines (to operate the machine and report its status)
Devices attached to an ACL controllers I/O ports (e.g. an automatic
screwdriver, a pneumatic gripper for a robot, etc.)

System Overview
Integration
In the previous sections you were given an overview of the entire cell. This section describes
the integration of various systems and devices by considering the sequence of events when a
part moves from station to station for processing.
When the user activates a production order, the CIM Manager builds a production plan. This
plan includes the parts to be processed, the stations where they are to be processed, and the
production activities they will undergo.
In the sample scenario presented below, a cube moves from storage in the ASRS to a CNC
station where it is machined into a box. The table below provides a step-by-step description
of the flow of information throughout the CIM associated with making a box. Note that
operations which are listed in the same grid take place concurrently.
Message Source Message Message Content
Destination (Command messages in normal typeface)
(Status messages in italics)
ASRS Station
CIM Manager PLC Stop the next empty pallet that arrives at the
ASRS station.
PLC CIM Manager Empty pallet has arrived at the ASRS station.
CIM Manager Robot Controller Use robot to remove a template with a cube from
storage and place it on the pallet..
Robot Controller CIM Manager Template is in place on pallet.
CIM Manager PLC Release this pallet from the ASRS station. Stop
this pallet when it arrives at the CNC station.
PLC CIM Manager Pallet with cube has arrived at the CNC station.
CNC Station
CIM Manager Robot Controller Use robot to remove template from pallet and
place it on buffer of CNC Station.
Robot Controller CIM Manager Template with part is waiting on buffer of CNC
station.
CIM Manager PLC Release pallet from CNC station.
CIM Manager Robot Controller Use robot to place part in CNC machine.
Robot Controller CIM Manager Part is in CNC machine.
CIM Manager CNC Machine Use the CNC machine to ream a hole in the cube
to form a box.
CNC Machine CIM Manager Process complete. Box ready.
CIM Manager Robot Controller Use robot to place box on template in buffer.
CIM Manager PLC Stop next empty pallet at CNC station.
Robot Controller CIM Manager Box is in place on template.
PLC CIM Manager Empty pallet has arrived at CNC station.
CIM Manager Robot Controller Use robot to place template with box on pallet.

System Overview
Message Source Message Message Content
Destination (Command messages in normal typeface)
Robot Controller CIM Manager Template is in place on pallet.
CIM Manager PLC Release pallet from the CNC station. Stop this
pallet when it arrives at the Assembly Station ...

System Overview
3
Safety
The OpenCIM cell is a complex system containing many different machines, each
potentially dangerous if proper safety practices are not followed. Certain safe operating
practices apply to all, while others are device specific. This chapter presents the general
rules, followed by a brief discussion of the safety requirements of each component and
contains the following sections:
General Safety Rules, describes the general safety rules that must be
followed in the OpenCIM cell surroundings area.
Robot and Controller Safety, describes the safety rules that must be
followed when using the OpenCIM robots and controllers.
CNC Machine Safety, describes the safety instructions that must be
followed when using the OpenCIM CNC machines.
ASRS Safety, describes the safety instructions that must be followed
when using the OpenCIM ASRS storage systems.
Conveyor and PLC Safety, describes the conveyer and PLC safety
instructions.
In addition, the User Manuals for all robots and CNC machines contain full descriptions of
the safety procedures and warnings for these devices. The user is strongly urged to read these
manuals before working with the devices.
Do not approach any OpenCIM equipment before reading the safety guidelines in this
chapter.
Warning!

Safety
General Safety Rules
The following rules should be followed when in the vicinity of all moving machinery in the
CIM cell such as robots, ASRS, or conveyor.
Warning! Exercise caution whenever you are in the area of the CIM cell.
Be sure you know the location of the ON/OFF switch, and any
emergency shutoff switches, on the following equipment:
Robot controller
Pallet conveyor
CNC machines
Be alert since any idle piece of equipment could start up suddenly.
All CIM machinery can be turned on and off unexpectedly via
computer control.
Exercise special caution in the vicinity of robots since they can start
up without notice and move in unexpected ways.
Members of a group should be careful not to crowd too close around
moving equipment when observing the activities at a given station.
Do not come near a moving device when it is in operation. Be careful
that hair, clothes (especially loose sleeves) and jewelry are kept away
from the mechanism.
Do not stick your fingers into a device while it is in operation; they
may get caught in the mechanism.
Keep the work area clean and free of clutter.
Do not exceed the loading capacity of a device.
Turn off a device before attempting adjustments, performing
maintenance or measuring a part.

Safety
Robot and Controller Safety
Extreme caution must be exercised in the use of OpenCIM robots. Recklessness may cause
physical harm to the operator and other people in the vicinity.
Set up a protective screen or guardrail around the robot.
Make sure the robot base is properly bolted to a table or pedestal.
Otherwise, the robot may become unstable and topple during
operation.
Do not use physical force on the robot arm to change its position, or
for any other reason.
Be sure the robot arm has sufficient space in which to operate freely,
especially during homing.
Before connecting any input or output to the controller, and before
approaching or handling the robot, make that the controllers main
power switch is turned off.
Before opening the controller housing, be sure to unplug the
controller power cable from the AC power outlet. It is not sufficient
to switch off the power; the power supplies inside the controller still
contain dangerously high voltages.
Before removing any fuses, be sure to turn off the controller and
unplug the controller power cable from the AC power outlet.
To immediately abort all running programs and stop movement of all axes (e.g. robots):
Press the Abort or Emergency Stop key on the teach pendant (TP), or
Note
Press the controllers red Emergency button.
In ACL controller: Use the ACL command A <Enter>, or
in Scorbase, press the STOP icon on the toolbar.

Safety
CNC Machine Safety
The following list contains general safety instructions for the use of CNC machines. Be sure
you adhere to the safety rules for the specific machines included in your cell.
Always wear safety goggles when near the machine. Be aware that
some materials, such as the brass bars, spray chips while being
processed. Make sure all persons near the machine are protected.
Keep children and visitors away. Set up the machine so that children
or visitors unfamiliar with the machine cannot start it. Protect the
machine against unintentional use by removing the switch key.
Chuck parts and tools firmly and safely.
Perform measuring and chucking work only when the machine is at a
standstill.
Remove adjusting key and wrenches even when the machine is not
being used. Never attach chuck keys to a machine with a chain or
similar connector.
Always work with sharp tools.

Safety
ASRS Safety
This section describes the safety instructions that must be followed when using the
OpenCIM ASRS storage systems (ASRS Carousel, ASRS2, ASRS-36, ASRS-36u, ASRS-
36uX2), each of which is described in the sections that follow.
ASRS Carousel
The following list contains safety instructions for the use of ASRS Carousel:
Do not place your hand or any other object in or near the main drive
belt, located under the lowest level of the ASRS carousel, while the
device is operating. The belt is extremely dangerous and can cause
severe injury.
Make sure that the carousel has been disconnected from the AC
power supply before approaching the motor and belts.
ASRS2 and ASRS-36

The following list contains safety instructions for the use of ASRS2 and ASRS-36
Do not enter the robots working envelope or touch the robot when
the system is in operation.
2
Use caution when moving the ASRS and ASRS-36 robots by means
of the teach pendant.
2
To halt movement of the ACL robots which tend the ASRS and
ASRS-36 units, do any of the following:
Press the Abort or Emergency Stop key on the teach pendant, or
Press the controllers red Emergency button, or
Use the ACL command A <Enter>.
ASRS-36u and ASRS-36uX2

The following list contains safety instructions for the use of ASRS-36u and ASRS-36uX2:
Do not enter the robots working envelope or touch the robot when it
is in operation.
Excercise caution when moving the ASRS-36u and ASRS-36uX2
robots by means of the teach pendant.
To halt movement of the USB robot which tends the ASRS-36u and
,ASRS-36uX2 units, do any of the following:
Press the Abort or Emergency Stop key on the teach pendant, or
Press the controllers red Emergency button, or
Use the Stop icon in the Scorbase software toolbar.
Opening any of the plexiglass doors which enclose the ASRS2 will automatically and
immediately halt all movement of the ASRS robot. Upon closing the door, movement will
Note
resume.

Safety
Conveyor and PLC Safety
The following list contains the conveyer and PLC safety instructions:
Be sure you know the location of the conveyors power ON/OFF
switch. To immediately stop the conveyor, simply shut off this switch.
Keep hands and objects away from the conveyor drive unit.
Do not tamper with the conveyor motor. Do not remove the conveyor
motor covers under any circumstances.
Do not touch or tamper with the power supply inside the PLC near
the conveyor motors.
Do not tamper with the switch and connector box for the
100/110/220/240/380V AC power supply (depending on device)

Safety
4
Installation
This chapter describes the hardware assembly processes, the wiring connections, the
software installation and configuration procedures and system verification and more. It
OpenCIM Installation Workflow, describes the required order for
installing the OpenCIM system components.
Hardware Installation, describes the assembly instructions of the
hardware components of the OpenCIM system.
Wiring, describes the wiring connection procedures of the hardware
components in the OpenCIM system.
Software Installation, describes the network setup and the
OpenCIM software installation and configuration.
Robot Positions and Homing, describes how to teach the robot
positions at the OpenCIM stations.
System Check, describes the verification and adjustment procedures
of the hardware components and device drivers.

Installation
OpenCIM Installation Workflow
The OpenCIM system is normally installed in the following order:
1. Hardware Assembly, described in Hardware Installation.
2. Wiring connections including network hardware, described in Wiring.
3. Software installation including software protection keys and network setup, described
in Software Installation.
4. Teaching of robot positions, described in Robot Positions.
5. Checking and adjustment of devices, for standalone and system operation, described in
System Check.
OpenCIM hardware configurations vary. This chapter presents the basic guidelines for
setting up CIM equipment. Additional installation instructions will be provided separately
for the specific equipment and configuration of your OpenCIM cell.

Installation
Hardware Installation
Before installing the OpenCIM, examine it for signs of shipping damage. If any damage is
evident, contact your freight carrier, and begin appropriate claims procedures.
Make sure you have received all the items listed on the shipment's packing list. If anything is
missing, contact your supplier.
For personal safety and for sufficient access to the stations from all open sides, a free area of
at least one meter around each station is recommended.
Be sure you comply with all safety guidelines and warnings in the user manuals supplied
with the robot, controller and other devices.
Some stations may have tables with slotted surfaces or predrilled holes to facilitate the
mounting of the robots and devices.
Conveyor and Pallets

Refer to the instructions provided with your conveyor and/or OpenCIM cell.
Set up the conveyor within reach of the power supply and the air supply.
Assemble the conveyor and attach the conveyor buffers at each station.
Make sure the conveyor is assembled so that it moves clockwise or counterclockwise
depending on your specific system layout.
Place the pallets supplied with the system anywhere along the conveyor with the arrow on
the pallet pointing in the direction of movement of the conveyor.
Robots and Robot Controllers

The basic steps for installing a robotic system for use in the OpenCIM cell are described
below:
1. Setup the robotic system according to the instructions in the Users Manual supplied
with the robot/controller.
2. Interface the robotic system with relevant accessories (I/O devices and so on.)
3. Once the robotic system is functional, create a communication interface using the
OpenCIM software.
For detailed instructions on connecting the robot and controller, refer to the Users Manual
supplied with the robot/controller. In addition, refer to the instructions provided with your
OpenCIM cell.
ASRS
Most ASRS systems are pre-assembled units that have to be placed near a conveyor station
so that pallets can be loaded/unloaded. If you customize the ASRS make sure that the
tending robot can reach all relevant elements and optimize the layout with respect to the
tending time of the robot.
Refer to the instructions provided with your ASRS and/or OpenCIM cell.
Barcode Reader
The standard Barcode reader is normally mounted within robot reach on the conveyor next to
the ASRS stop station in order to check outgoing and incoming template IDs. It requires a
5.6V DC power supply and a RS232 connection either to the Station PC or to the robot
controller.
Refer to the instructions provided with your barcode reader and/or OpenCIM cell.

Installation
RFID Reader
RFID (Radio-frequency Identification) is a commonly used automatic identification
technology that transmits an identification serial number using radio waves.
The standard RFID reader is normally mounted within robot reach on the conveyor next to
the ASRS stop station in order to check outgoing template IDs. It requires a 12V DC power
supply and an RS232 or USB port on the Station PC.
Refer to the instructions provided with your RFID reader and/or OpenCIM cell.
Pneumatic Devices
Pneumatic devices in a station (pneumatic door, fixtures, caliper, air blows, etc.) including
position sensors are normally interfaced through the I/Os of the robot controller. They can
also be controlled by a separate PLC if requested by the customer. In any case, pneumatic
devices require the appropriate supply of compressed and conditioned air.
Refer to the instructions provided with the specific device and/or OpenCIM cell.
Palletizing Racks and Buffers

Normally, buffers are mounted on the conveyor but, for a specific station layout, it is
possible to attach them to a table. Palletizing racks are used as a flexible storage that can be
adapted to various parts by using sets of different sized pins. Make sure the pins are arranged
identically for each part of the same type in the palletizing rack.
Refer to the instructions provided with the OpenCIM cell.
Templates
Templates are used to transport parts within the system. Templates, which have a grid of
holes together with different sized pins, allow flexible adjustment for different parts in a
similar way to the palletizing racks. Make sure the pins are arranged identically on all
templates which will hold identical parts.
Refer to the instructions provided with the OpenCIM cell.

Installation
Wiring
Wiring depends on the actual stations, machines and devices included in your OpenCIM
installation. Most systems are installed by a trained engineer who will supply you with
specific wiring documentation (communication layout) to enable you to easily understand
and maintain the system.
Refer to the documentation and wiring instructions provided with the OpenCIM cell.
Network
It is possible to operate the OpenCIM on any desktop or laptop PC which complies with the
required hardware specifications in which a network board (adapter) has been installed,
providing that you have installed the software driver which enables the adapter to work with
the Windows Operating System. For further details, see Network Setup. Network wiring,
which is documented in the communication layout, is performed through a hub.

Installation
Software Installation
This section describes how to set up the OpenCIM network as well how to install and
configure the various OpenCIM software components such as the OpenCIM projects, the
web viewer and more.
Network Setup
Once Windows has been installed and all PC devices (CD ROM drive, mouse, graphic card,
network card, and so on ) have been set up on each PC that is to be used in the OpenCIM
network, set up the network as described in the following procedure:
To set up the network:
1. Define the Network Workgroups and computer names. Computer names are case-
sensitive. It is recommended that you use names such as these:
Network Workgroup CIM
CIM Manager PC CIM-MANAGER
Station PCs CIM-PC1, CIM-PC2, etc. on which the logical workstations
(WS1, WS2, etc.) of the CIM are located
2. Set the TCP/IP network protocol as your communication protocol. Select the IP address
as follows: If your network Workgroup is part of a global network (i.e. is connected to a
server) choose the option: Obtain an IP address automatically.
If your network workgroup is local (i.e. not connected to a server) set the IP address, for
example, as 200.1.1.1 and increment the last digit for each additional PC.
For all PCs in the CIM, specify the same subnet mask, for example, 255.255.0.0. For
details, contact your network administrator.
3. If you are using more than one PC, it is a good idea to verify that the PCs are connected
to the network.
To see the names of the connected PCs, follow one of the procedures outlined below.
In Windows XP:
Click Start | My Network Places | Entire Network (In the Other Places section area
on the left of the window.)
In Windows Vista/7:
Click Start | Network
If you dont see the PC names, wait a few seconds and press F5. If the names are still
not displayed, check the network setup again.

Installation
Installing the OpenCIM Software
After setting up the network, the next step is to install the OpenCIM software. The following
procedure describes how to install one of the OpenCIM products (OpenCIM, OpenCIM
Offline, OpenFMS). You can cancel the setup process at any time by pressing Cancel.
By default, the software will be installed in the path X:\program files\intelitek\opencim

(where X is the system drive) . If you already have a previous version of the software in a
Notes
directory of this name, select a different directory name for the new installation.
Installation of multiple products on the same PC is permitted provided that you have a
license for each product.
To install the OpenCIM software:
1. Close all open applications and insert the OpenCIM software CD into the CD ROM
drive.
Autorun begins the installation process as soon as you insert the CD unless you
hold the SHIFT key while you insert the CD.
If you have turned off Autorun, you must specify the CD ROM drive from which
to run the installation setup file which will begin the installation. From the
Windows Start menu, choose Run. Enter:
X:\install\setup [where X represents the CD ROM drive].
2. In the Welcome window of the Installation Wizard choose Next. The License
Agreement window will appear.
Figure 4-1: License Agreement Window

Installation
3. Review the Intelitek software license agreement. You must accept the terms of this
agreement in order to complete the installation. If you do not accept the agreement, you
cannot proceed with the installation. To accept, click Yes. The Installation Mode
window will appear.
Figure 4-2: Installation Mode Window

Installation
4. Select the OpenCIM product that you want to install and click Next. The Project
Selection window will appear.
The WorkStation Environment option is used (by Intelitek technical support

personnel) to install system components necessary to run device drivers from a PC
Note
which is not the CIM Manager PC. For further details, see Software for WorkStation
PCs.
Figure 4-3: Project Selection Window

5. Select the required projects to install.
6. Select the required option as follows:
Select OpenCIM Projects to add the default OpenCIM projects to your existing
OpenCIM installation.
Select OpenCIM Curriculum Projects to add the OpenCIM Curriculum
Projects to your existing OpenCIM installation.
You can select one or both of the above.

Note

Installation
7. Click Next. The Web Viewer Configuration window will appear.
Figure 4-4: Web Viewer Configuration Window

Installation
8. Check the Web Viewer box and click Next to add the Internet Information Services
(IIS) Web Server (necessary for the web viewer), and to configure the Web Server to
work with the Web Viewer. The Choose Destination Location window will appear.
In XP, for the Web Server to be installed, the installation CD must be inside the
computer.
Note
Figure 4-5: Choose Destination Location Window

Installation
9. Click Next to install to the default folder, or click Browse and choose another folder.
The Select Program Folder window will appear.
Figure 4-6: Select Program Folder Window

10. Click Next to accept the default Program Folder name. (You may also type a new
folder name or select another folder from the existing folders list.)
11. The installation progress bar is displayed on the screen. When prompted by the on-
screen instructions, click Ok to install the Project Manager launch icon on your desktop.

Installation
12. The Installation Complete window is displayed when installation has been successfully
completed as shown in Figure 4-7.
Figure 4-7: Installation Complete Window.

13. Click Finish to exit the InstallShield Wizard.
The Project Manager launch icon is added to the Desktop.
Project Manager can also be initialized by clicking on Project Manager which can be
accessed by clicking Start | All Programs | OpenCIM.
The OpenCIM Applications, CIM Manager and CIM Setup are both activated
from the Project Manager application which can be launched from the desktop shortcut icon
or from the OpenCIM popup menu
Refer to Chapter 5, CIM Project Manager for further details.
A shortcut to the folder containing the projects that were installed is also added to the Desktop
and the Start menu.

Installation
Installing OpenCIM Projects
The OpenCIM Installation wizard enables you to add OpenCIM Projects to an existing
installation, as described in the following procedure.
To install OpenCIM Projects:
drive.
X:\install\setup [where x represents the CD ROM drive].

Installation
window is displayed.
Figure 4-9: Installation Mode Window. Installing Projects.

Installation
4. Select Projects and then choose Next. The Project Selection window is displayed.
Figure 4-10: Project Selection Window

5. Select the required option as follows:
Select OpenCIM Projects to add the default OpenCIM projects to your existing
Select OpenCIM Curriculum Projects to add the OpenCIM Curriculum
Projects to your existing OpenCIM installation.
You can select one or both of the above.

Note

Installation
6. Click Next. The Project Installation Mode window is displayed containing the software
installation modes that contain the project or projects that were chosen in the previous
step).
Figure 4-11: Project Installation Mode Window

7. Select the appropriate project installation mode and Click Next. The OpenCIM
Installation wizard begins to install the selected projects onto your computer. When the
installation is complete. The InstallShield Wizard Complete window is displayed.
8. Click Finish to exit the Wizard. The selected projects will be displayed in the Archive
tab, the next time you activate the Project Manager application.
The default destination for the projects is:
Windows XP: [default system drive (for example C:)]\Documents and Settings\All
Notes
Users\Documents\Intelitek\OpenCIM\Projects
Windows Vista/7: [default system drive (for example C:)]\Users\Public
Documents\Intelitek\OpenCIM\Projects

Installation
Manual Web Viewer Installation
It is recommended that you choose to install and configure the Internet Information Server
(IIS) automatically by checking the box in the Web Viewer Configuration window which
appears during the OpenCIM installation procedure.
The following section describes how to install the Internet Information Server (IIS) and
configure the Web Viewer manually.
After installing the OpenCIM software, the Web Viewer can be installed and configured
manually as shown in the steps outlined below:
Installing the IIS, describes the installation procedure for the
Internet Information
Server (IIS).
Configuring the Web Viewer, describes the configuration of the
web server in Windows XP and Windows Vista/7.
Installing the IIS
In Windows XP:
To install the IIS manually in Windows XP, you are required to insert the Windows XP
Operating System CD into the CD drive and follow these steps:
1. From the Windows Start menu select Settings | Control Panel | Add or Remove
Programs
2. Select Add/Remove Windows Components
The Windows Components Window is displayed as shown in Figure 4-12.
Figure 4-12: Windows Components Window

Installation
3. Select the Internet Information Services (IIS) checkbox and click Next to proceed to
the next step where you will configure the components.
4. When the configuration is complete the final window is displayed.
Figure 4-13: Windows components Wizard-Final Window

5. Click Finish to complete the installation.

Installation
In Windows Vista/7:
1. From the Start menu select Control Panel | Programs | Programs and Features | Turn
Windows Features On or Off (In the Tasks area on the left of the window.)
2. Click Continue on the security dialog box or if you are an administrator, enter your
administrator account information and click Continue. The Windows Features window
is displayed.
Figure 4-14: Windows Features Window Internet Information Services

3. Expand Internet Information Services | Web Management Tools | IIS 6
Management Compatibility. Verify that all its branches are checked as shown in
Figure 4-14.
4. Expand Internet Information Services | Web Management Tools | World Wide Web
Services | Application Development Features and check the following branches:
ASP
ISAPI Extensions
The screen should now appear as follows:

Installation
Figure 4-15: Winows Features Window- World Wide Web Services
5. Click OK.
6. After the IIS installation is complete, you can add an Internet Information Services icon
on your desktop, as follows:
From your windows Start menu, select Control Panel | System and
Maintenance | Administrative Tools The Administrative Tools window is
displayed.
Right-click Internet Information Services IIS Manager. From the displayed
popup menu select Create Shortcut. When prompted, click Yes to create a
shortcut on your desktop.
To restart the IIS press the Start button. To stop the IIS server press the Stop button.
Note
Configuring the Web Viewer

After installing the IIS manually, the next step is to configure the Web Viewer. When
reinstalling or upgrading the Open CIM application, the configuration procedures described
in this section are not required.
This section describes how to configure the Web Viewer in Windows XP, Vista and 7.
In order for the Web Viewer to work when the firewall is enabled, Port 80 in the firewall
must be opened.
Note
Configuring the Web Viewer in Windows XP, Vista and 7

The following procedure describes how to configure the web viewer in the Windows XP,
Vista or 7 operating systems.
To configure the web viewer in Windows XP/Vista/7:

Installation
1. From your windows Start menu, select Run. The Run window is displayed.
2. Type dcomcnfg in the Open field and click OK. The Component Services window is
displayed as shown in Figure 4-16.
In Windows Vista/7, a security dialog box will be displayed. Click Continue (if you are not
the Administrator you will be prompted to enter your user name and password to continue).
Figure 4-16: Component Services Window

3. Browse to Component Services | Computers | DCOM Config in the tree menu in the
left pane.

Installation
4. Right-click Manage Document and select Properties. The Manage Document
Properties window appears displaying the General tab.
Figure 4-17: Manage Document Properties Window- General Tab

5. From the Authentication Level dropdown list, select None.

Installation
6. Select the Identity tab, as shown in Figure 4-18.
Figure 4-18: Manage Document Properties Window-Identity Tab

7. Select The interactive user and click Apply and then OK to close the Management
Document Properties window.
To change security settings, repeat steps 1-5 above, and proceed as follows:

Installation
1. Select the Security tab as shown in Figure 4-19:
Figure 4-19: Manage Document Properties-Security Tab

Installation
2. In the Launch and Activation Permissions area, select Customize and click Edit. The
Launch and Activation Permission window is displayed. (In Windows XP, this window
is called the Launch Permission window).
Figure 4-20: Launch and Activation Permission Window

3. Select the Allow check boxes for Local Launch and Local Activation.
4. Click Add | Advanced | Find Now
5. Scroll through the list of search results to find the following user:
In Windows XP: IUSR_<your computer name>.
In Windows Vista/7: IUSR
6. Double click the name.
7. Click OK.

Installation
8. Return to the Manage Document Properties window. In the Access permissions area in
the Security Tab, select Customize and click Edit.
Figure 4-21: Access permissions Window

9. Repeat steps 4 to 7.
10. Select Allow for Local Access in the Access Permissions window.
11. Click OK.
12. Restart your computer, in order for the changes to take effect.
Before you can activate the Web Viewer, you must activate the Web Viewer in the CIM
Modes window, accessed from the Modes button on the CIM Manager toolbar, as
described in Modes Dialog Box in Chapter 6, Operating CIM Manager. In addition, the
HTTP protocol must be enabled in order to access the Web Viewer.

Installation
Software for Workstation PCs
In order to be able to use OpenCIM modules on a station PC, you must install the
Workstation software from the OpenCIM installation CD.
For workstation PCs which require Viewflex and/or Scorbase software, it is highly
recommended that they be installed before the installation of the Workstation
Note Environment.
They can however be defined manually within the project directory by modifying the
configuration files which they use. Refer to Chapter 12 OpenCIM Loader:
DDLoader.EXE for more details.
Microsoft .Net Framework 4.0 is required on the client PC for the use of the OpenCIM
RFID driver, and will be installed automatically if it is not already installed on the
Note workstation PC.
Installing the Workstation Software

To install Workstation software:
drive.

Installation
X:\install\setup [where x represents the CD ROM drive].

Installation
window will appear.
Figure 4-23: Installation Mode Window

Installation
4. Select Workstation Environment and click Next. The Choose Project window will
appear.
Figure 4-24: Choose Project Window

5. Browse to the location of the project that the workstation environment will be using and
click Next. The Select a Workstation window will appear.
Figure 4-25: Select a Workstation Window

Installation
6. Select the workstation to install, and Remote Graphic Display if desired (Refer to
Chapter 6: Operating CIM Manager for information on configuring the Remote
Graphic Display). Several Workstations may be installed on one computer. Click Next.
If the workstation you are installing uses Viewflex, the Viewflex Path window
will appear. Refer to the next step.
If the workstation you are installing uses Scorbase, the Scorbase Path window
will appear. Refer to step 8.
If the workstation does not require Viewflex nor Scorbase, skip to step 9.
Figure 4-26: Viewflex Path Window

Installation
7. Browse to the location of Viewflex on your system and click Next. The Viewflex Path
window will appear.
If you have not yet installed Viewflex, click Skip to continue the installation process.
Note
Figure 4-27: Scorebase Path Window

Installation
8. Browse to the location of Scorbase on your system and click Next. The Choose
Destination Folder window will appear.
If you have not yet installed Scorbase, click Skip to continue the installation process.
Note
Figure 4-28: Choose Destination Location Window

9. Browse to the folder in which you want to install the Workstation Environment files
and click Next. The installation will begin.
Shortcuts for the DDLoaders for the installed Workstations, and for the Remote Graphic
Display if it was installed, will be added to the Desktop and to the Start menu.
Configuring Workstations
To use the OpenCIM modules on a station PC, ensure that you perform the following
procedures:
On the CIM Manager and all Workstations, configure the firewall
for communication with other Workstations in the local network.
On all Workstations, enable all workstations in the local network to
access the Manager PC Drive in which the projects are installed by
sharing the projects folder.
Note: In order to work with the Remote Graphic Display with CIM
custom parts displayed correctly on the Workstation, the following
folder must be shared:
In Windows XP: [default system drive (for example C:)]\Documents and
Settings\All Users\Documents\Intelitek\OpenCIM\.
In Windows Vista/7: [default system drive (for example
C:)]\Users\Public\Documents\Intelitek\OpenCIM\.

Installation
Firewall Configuration
If the firewall of a Workstation is enabled, ports must be opened for them for the
Workstation to be used in the local network. Open the Map.ini file to see which ports to
open. For more details on this file, refer to Chapter 12: Inside OpenCIM.
In order for the Web Viewer to work, Port 80 must also be opened in the firewall.
Enable Access to CIM Manager

In Windows Vista/7, before you begin you must verify that the settings displayed in Figure
4-29 are on, to enable you to set the folders for sharing.
Figure 4-29: Sharing and Discovery Window

To verify that the correct options are on, follow these steps:
1. Click Start | Control Panel | Network and Internet | Network and Sharing Center.
2. In the Sharing and Discovery area, ensure that the first three items are on, as illustrated
in Figure 4-29.
The projects are installed in the following locations:
In Windows XP: [default system drive (for example C:)]\Documents
and Settings\All Users\Documents\Intelitek\OpenCIM\Projects.
C:)]\Users\Public\Documents\Intelitek\OpenCIM\Projects.
In Windows XP for example, to share folder X:

1. Select My Computer.
2. Find folder X
3. Right-click on the folder and select Sharing And Security. The folders Properties
4. Select Share this folder.
5. Click Permissions. The folders Permissions window is displayed.
6. Check the Full control option to allow other users to modify the files.
7. Click OK.
8. In the Properties window, click OK.
In Windows Vista/7:
1. Click Start | Computer.
2. Browse to and right-click the required folder.
3. Select Properties | Sharing | Advanced Sharing (if you are not the administrator you
will need to enter the user name and password).

Installation
4. Click Continue.
5. Select Share this folder.
6. Confirm that the Share name is correct.
7. Click Permissions.
8. Check the Full Control option.
9. Click OK.
10. In the Advanced Sharing window click OK.
11. In the Properties window click Close.
On the Station PCs, map the drive of the Manager PC (where the projects are installed)
through the network, as follows:
1. Select and right-click My Computer.
2. Select Map Network Drive.
3. Select a free drive and write the path for the Managers projects directory.
For example: Drive E: <path> \\Manager\Projects.
4. Check Reconnect at Logon and click OK.
On the Remote Graphic Display Station PC, map the drive of the Manager PC (where the
OpenCIM shared directory is located) through the network, as follows:
1. Select and right-click My Computer.
2. Select Map Network Drive.
3. Select a free drive and write the path for the Managers projects directory.
For example: Drive E: <path> \\Manager\OpenCIM.
4. Check Reconnect at Logon and click OK.
Other Software
An OpenCIM system can include many devices which require additional software (e.g.,
Vision Systems, CNC machines, CAD/CAM, etc.).
Refer to the documentation and software installation instructions provided with each device.

Installation
ACL Controller Configuration
The following procedure is valid only for ACL controller types A and B. For other
controllers, refer to the documentation and software installation instructions provided with
each device.
At each station which contains an ACL controller, you will need to configure the controller
and download the file ALL.CBU from the Station Manager PC to the ACL controller. This
file contains all programs, positions and parameters required for controller operation in the
OpenCIM environment.
To configure the controller from the ATS main screens:
1. Press <Ctrl>+F1 to configure the controller.
2. Press Y to confirm the prompt to configure the controller. You are then prompted by a
short series of Controller Configuration options. Refer to the ATS Reference Guide
provided with your ACL controller for complete instructions on configuring the
controller.
Once you have confirmed the configuration, ATS will perform the configuration procedure.
You can ignore the message about the missing SETUP.PAR parameter file.
3. When the > prompt appears, press [Shift] + F10. The ATS Backup Manager screen
opens.
4. Perform the following selections and entries:
Backup directory:
In Windows XP: [default system drive (for example
C:)]\Documents and Settings\All
Users\Documents\Intelitek\OpenCIM\Projects\microcim\ws1\rob
ot1
C:)]\Users\Public\Documents\Intelitek\OpenCIM\Projects\micr
ocim\ws1\robot1.
Make sure the path correctly shows the working directory defined during the configuration,
as shown in this example.
Backup / Restore: ALL
5. Use the arrow keys to highlight ALL and press [Enter].
During Restore: ERASE.
6. Use the arrow keys to highlight ERASE and press [Enter].
File name: all
7. Type ALL and press [Enter].
8. Press [Enter] again. Press F5 to RESTORE from disk.
9. Press Y to confirm all prompts to overwrite and erase.

Installation
Scorbase and Scorbase PRO Configuration
At each station which uses Scorbase, you will need to configure the software to match the
robot and peripherals that the Controller will control.
To configure Scorbase, select Options | Hardware Setup from the Menu bar in Scorbase.
Configure the settings in the Hardware Setup dialog box to match the robot and peripherals
(and gripper if appropriate), that will be controlled by the Controller. Once you have
configured the Hardware Setup, click the Search Home icon to home the robot.
Note: Scorbase must be in On-line mode before configuring the Hardware Setup. To change
to On-line mode, select Options | On-line from the Menu bar.
For more information on configuring Scorbase, refer to the Scorbase for SCORBOT-ER 4u
and Scorbase for ER 9Pro/ER 14Pro User Manuals.

Installation
Robot Positions and Homing
The actual location of robot positions will differ depending on the actual stations, machines
and devices included in the OpenCIM installation. You will therefore need to record (teach)
new coordinates for the positions which were downloaded to the controller.
For further details on defining the positions, refer to the instructions supplied with your
OpenCIM installation. In addition, refer to the User Manual that is provided with the robot or
controller.
The procedures in this section describe how to home the robot from the ACL and USB
controllers. For other controllers, refer to the documentation and software installation
instructions provided with each device.
Homing the Robot from the ACL Controller

The following procedure describes how to home the robots from the ACL controller (types A
and B). The teaching of robot positions is performed from the ATS. You must home the
robot before you teach positions, as described in the following procedure.
To home robot from the ACL controller:
1. Enter the ACL command: RUN HOMES
2. Wait until the robot has completed the homing twice. All positions used in the
OpenCIM belong to the vector CIM[n]. The size of the vector can vary from station to
station. The standard size is n = 500. To teach the robot the positions required for the
application, you must attach this vector to the teach pendant. Enter the ACL command:
ATTACH CIM
3. When you have finished recording the positions, use the ATS Backup Manager to save
the programs, positions and parameters to disk. Save each item as a separate file. Make
the following selections and entries:
Backup directory:
In Windows XP: [default system drive (for example
C:)]\Documents and Settings\All Users\Documents\Intelitek\
OpenCIM\Projects\microcim\ws1\robot1
C:)]\Users\Public\Documents\Intelitek\OpenCIM\Projects\micr
ocim\ws1\robot1.
(for example)
Backup / Restore: ALL
File name: All
4. Press [Enter] again. Press F3 to SAVE to disk
Backup / Restore: PROGRAMS
File name: programs
5. Press [Enter] again. Press F3 to SAVE to disk.
Backup / Restore: POSITIONS
File name: position
Backup / Restore: PARAMETERS
File name: parameter

Installation
Homing the Robot from Scorbase
This procedure describes the basic instructions for homing the robot from the Scorbase
software. For additional information on homing and recording the positions, refer to the
Scorbase User Manual.
To home the robot from Scorbase:
1. Activate the Scorbase software, by double clicking the Scorbase icon on your
desktop.
2. From the Scorbase Main Window select Options | On-line to activate on-line mode and
click the icon to home the robot. Refer to the Scorbase User Guide for additional
details on homing and recording the robot positions.
3. Select File | Open Project and navigate to the required project file for this station. For
example:
In Windows XP:
\\CIM-MANAGER\Documents\intelitek\OpenCIM\projects\M-CIM-
SCBS\WS1\ROBOT1-program sample\Station1.WS.
In Windows Vista/7:
\\CIM-MANAGER\Public\Documents\Intelitek\OpenCIM\Projects\M-CIM-
SCBS\WS1\ROBOT1-program sample\Station1.WS.
Select the Reload last Project at Startup from the Options menu, to load this project
automatically the next time you load Scorbase.
Notes

Installation
System Check
The system check depends on the actual stations, machines and devices included in the
OpenCIM installation. Refer to documentation and instructions supplied with your OpenCIM
installation.
Check the following hardware and device drivers and make sure they are functioning
properly:
Power Supply
Conveyor
Robots (for ACL controller use the ACL program DEBUG)
PLC Device Driver
CNC Device Driver
Pneumatic Device Driver
Hydraulic Device Driver
Process Device Driver

Installation
5
Project Manager
This chapter describes the Project Manager application that launches the Virtual CIM Setup
and CIM Manager. It enables users to manage their own projects, and enables administrators
to manage the projects in the archive. It includes the following sections:
Accessing the Project Manager, describes how to access the Project
Manager application.
Project Manager Main Window, describes the main components of
the Project Manager interface.
Project Manager User Mode, describes the various project
management tasks that can be performed by the user. These include,
adding, importing and exporting projects and so on.
Project Manager Administration Mode, describes the additional
tasks performed by the administrators enabling them to manage the
projects displayed in the archives.
Installing the Web Viewer Server, describes how to install the Web
Viewer Server from within the Project Manager application.

Project Manager
Accessing the Project Manager
After the OpenCIM installation is complete, the Project Manager icon is displayed on your
windows desktop and Start menu.
To log in to the Project Manager application:
From the windows Start menu, select All Programs | OpenCIM |
Project Manager .
OR
Click the OpenCIM Project Manager icon on your desktop.
The CIM Project Manager window appears displaying the User Projects tab, as shown in
Project Manager Main Window in the following section.

Project Manager
Project Manager Main Window
The CIM Project Manager Main window is displayed, as follows:
Figure 5-1: Project Manager Main Window

The CIM Project Manager window, shown above, contains the following elements, each of
which is described in the sections that follow.
Project Manager Menu Bar
Project Manager Toolbar
Archive Tab
User Projects Tab
3D Model Display Area
A 3D model of the selected project is shown below the list of project names and
descriptions when 3D Model is selected from the View Menu. See View Menu below.
Notes

Project Manager
Project Manager Menu Bar
The Project Manager Menu bar contains four menus, each of which is described in detail in
the sections that follow.
Project Menu
The following table contains a brief description of each option in the Project menu:
Option Description
New Enables you to add a new project to the list.
Import Enables you to import an existing CIM Project from a specified directory.
This option is enabled from the User Projects tab only.
Save As Enables you to save the selected project under a new name. The new project
is displayed in the list of projects in the User Projects tab.
Load All Loads all the projects existing in the Projects directory into the User
Projects tab. This feature is used, for example, when upgrading your
OpenCIM, enabling you to load all previous projects that were created
previously. This option is enabled from the User Projects tab only.
Back Up Enables you to export a project to a specified directory for backup purposes.
You can export projects from both the User Projects and Archive tab.
Delete Removes a project permanently from the list as well as from your computer.
You must have administrator access rights to remove projects from the
Archive.
Exit Exits the project manager application.
View Menu
The following table contains a brief description of each option in the View menu.
Option Description
Toolbar Shows or hides the OpenCIM toolbar.
3D Model Shows or hides a 3D view of the selected project, in the 3D Model Display
area.
Tools Menu
The following table contains a brief description of each option in the Tools menu.
Option Description
CIM Manager Activates the CIM Manager application, with the selected project from the
User Projects list.
CIM Setup Activates the CIM Setup application, with the selected project from the
User Projects list.
Login as Enables you to log in as an administrator.
Administrator
Move to Moves the selected project from the User Projects tab to the Archive tab.
Archive Enabled for administrator's only.
Move to User Moves the selected project from the Archive tab to the User Projects tab.
Projects Enabled for administrators only.

Project Manager
Help Menu
The following table contains a brief description of each option in the Help menu.
Option Description
Help Displays the OpenCIM online help.
About Displays the About Project Manager window contaning the current
software version information.
Project Manager Toolbar

The toolbar icons provide quick access to the most commonly used functions in the CIM
Project Manager window and appear as follows:
The following table contains a brief description of each option on the CIM Project Manager
toolbar:
Option Description
New: Enables you to add a new project to the list.
Import: Enables you to import an existing CIM Project from a local

directory. This option is enabled from the User Projects tab only.
Save As: Enables you to save the selected project under a new name.
The new project is displayed in the list of projects in the User Projects
tab.
Back Up: Enables you to export a project to a specified directory for
backup purposes. You can export projects from both the User Projects
and Archive tabs.
Delete: Removes a project permanently from the list as well as from
your computer. You must have administrator access rights to remove
projects from the Archive.
CIM Manager: Activates the CIM Manager application, with the
selected project from the User Projects list.
CIM Setup: Activates the CIM Setup application, with the selected
project from the User Projects list.
Administrator: Enables you to log in as an administrator.
Move to Archive: Moves the selected project from the User Projects
tab to the Archive tab. Enabled for administrator's only.
Move to User Projects: Moves the selected project from the Archive
tab to the User Projects tab. Enabled for administrators only.
Help: Displays the OpenCIM online help.

Project Manager
User Projects Tab
The User Projects tab appears automatically when you access the Project Manager
application. The User Projects tab contains a list and description of the user's projects and
enables you to perform the following:
Create new CIM projects.
Import projects from an external directory into the user projects list.
Export projects from the user projects list to an external directory for
backup purposes.
Perform various editing options, such as, save as, delete, move to
archive and more.
Access the CIM Setup or CIM Manager applications.
The User Projects tab appears as follows:
Figure 5-2: CIM Project Manager User Projects Tab

Project Manager
3D Model Display Area
When View | 3D Model is selected from the menu bar, the selected project is displayed in a
three dimensional view in the 3D model display area. You can zoom in and zoom out, rotate
the image and adjust the viewing angle of the image, using the viewing options described in
CIM Managers graphic display module described Graphic Display and Tracking in Chapter
6, Operating CIM Manager.
Figure 5-3: CIM Project Manager User Projects Tab 3D Model View

Project Manager
User Projects Right Click Menu
The User Projects right-click menu provides alternate quick access to some of the most
commonly used functions in the User Projects tab of the CIM Project Manager window. To
access the menu, select a project and then right click on the project name. The menu appears
as follows:
The options in the right-click menu shown above are described in the Project Manager
Toolbar and Project Manager Main Window sections of this chapter.

Project Manager
Archive Tab
The Archive tab contains a list and description of all the predefined projects that are
provided with the OpenCIM software and enables you to perform the following:
Copy projects to the user projects list (users and administrators)
Save projects to an external location for backup purposes. (users and
administrators)
Perform various editing options, such as delete, move to user projects
and more (administrators only).
The Archive tab appears as follows:
Figure 5-4: CIM Project Manager Archive Tab
Archive Tab Right-Click Menu

The Archive Tab right-click menu provides alternate quick access to some of the most
commonly used functions in the Archive tab of the CIM Project Manager window. To access
the menu, select a project and then right click on the project name. The menu appears as
follows:
The options in the right-click menu shown above are described in the Project Manager
Toolbar and Project Manager Main Window sections of this chapter.

Project Manager
Project Manager User Mode
The Project Manager application enables users to manage their CIM projects from the User
Projects tab. The tasks that the user can perform include adding projects, importing and
exporting projects, copying projects and more.
Adding Projects
You can add new projects from the User Projects tab in the CIM Project Manager window.
After you have created your project you can then activate the CIM Setup or CIM Manager
applications for the selected project.
To add projects:
1. In the User Projects tab, click New on the toolbar. The Save As dialog box is
displayed.
Figure 5-5: Save As Dialog Box

2. In the Project name field, enter the name of the new project, and click OK. The new
project is added to the list of projects in the User Projects tab.
You can now select the new project in the User Projects tab and then select the required
option, as follows:
CIM Setup : Activates the Virtual CIM Setup application to

enable you to edit your simulated CIM cell of the project. (For
further details refer to Chapter 7, OpenCIM Setup).
CIM Manager : Activates the CIM Manager application,

enabling you to centrally control all the activities of the OpenCIM
cell. (For further details refer to Chapter 6: Operating CIM
Manager).
Importing Projects
The Project Manager enables users to import existing CIM projects into the User Projects tab
from a specified directory.
To import projects:
1. From the User Projects tab, select Import . The standard Open dialog box is
displayed. Navigate to select the file to import and click Open. The Open dialog box is
displayed.
2. Navigate to the required directory and select the project (containing the *.O2C format)
that you want to import.

Project Manager
3. Click Open. The selected project is displayed in the list of projects in the User Projects
tab.
Exporting Projects
The Project Manager enables users to export an existing CIM Project from the User Projects
or Archive tab to a specified directory, for future reference.
To export projects:
1. From the User Projects tab, select the project that you want to export.
2. Select Backup from the toolbar. The standard Save As dialog box is displayed.
Navigate to select the directory to export and click Save. The project will be saved in
the selected directory.
Loading All Projects

The Project Manager enables users to load all the projects that exist in the OpenCIM
directory into the User Projects tab. This option is enabled from the User Projects tab only
To load all projects:
From the User Projects tab, select Project | Load All. All the projects that exist in your
Projects directory on your computer will be displayed in the User Projects tab. This feature is
used for retrieval purposes and can be useful when upgrading your OpenCIM, enabling you
to load all the previous projects created previously.
Copying Projects
The Project Manager enables users to create a copy of the selected project by saving it under
a new name. The new project is then displayed in the list of projects in the User Projects tab.
To copy projects:
1. From the User Projects or Archive tab, select the project that you want to copy, and
click Save As . The Save As dialog box is displayed:
Figure 5-6: Save As Dialog Box

2. In the Project name field, enter the new project name and click OK.
3. The new project is added to the list of projects in the User Projects tab.
The Save As option always displays the new project to the User Projects tab (even when you
select this option from the Archive tab).
Note

Project Manager
Removing Projects
When removing projects from the User Projects tab, you must act cautiously since the
project is removed permanently from your computer. Only administrators can remove
projects from the Archive tab.
To remove projects:
1. From the User Projects tab, select the project that you want to remove.
2. Click . Delete. The selected project is removed from the User Projects list.
Accessing CIM Manager

The CIM Manager application enables users to centrally control all the activities of the
selected CIM cell. For further details refer to Chapter 6, Operating CIM Manager.
To access the CIM Manager:
1. From the User Projects tab, select the project for which you want to access the CIM
Manager.
2. Select CIM Manager to activate the CIM Manager application, enabling you to
control all the activities of the OpenCIM cell.
(For further details refer to Chapter 6, Operating CIM Manager).
Accessing CIM Setup

The CIM Setup application enables users to create and modify the CIM Setup of the selected
cell. For further details refer to Chapter 8, OpenCIM Setup.
To access the CIM Setup:
1. From the User Projects tab, select the project for which you want to access the CIM
Setup.
2. Select CIM Setup to activate the CIM Setup application, enabling you to edit your
simulated CIM cell of the selected project.
(For further details refer to Chapter 8, OpenCIM Setup).

Project Manager
Project Manager Administration Mode
In addition to all the tasks described in the Project Manager User Mode, the Project Manager
application also enables administrators to manage the projects displayed in the archives.
These include, moving projects from the user projects list to the archives and from the
archives to the user list and more.
Defining Administrator Access Rights

After entering your administrators' password, (described below) you are granted additional
access rights to the system, enabling you to add, remove, import and export projects from the
Archive tab and more. You must enter this administrators' password each time you enter the
Project Manager application.
To log in as an administrator:
1. Click on the toolbar. The Administrator dialog box is displayed.
Figure 5-7: Administrator Dialog Box

2. In the Password field, enter mypassword and click OK. You now have administrator's
access rights.
Moving Projects to Archive

Administrators can move projects from the User Projects to the Archive. This is used for
example when you want to define a project as read-only.
To move projects to the Archive:
From the User Projects tab, select the project to move to the Archive tab and
click Move to Archive. The selected project is removed from the User Projects tab and
displayed in the Archive tab.
Moving Projects to User Projects tab

Administrators can move projects from the Archive tab to the User Projects tab. This is used
for example when a project is no longer required in the archive, but is required for the users.
To move projects to the user projects tab:
From the Archive tab, select the project to move to the User Projects tab and
click Move to User Projects. The selected project is removed from the Archive tab
and is displayed in the User Projects tab.

Project Manager
Installing the Web Viewer Server
1. To install the Web Viewer Server select Tools | Web Viewer Server Setup from the
Menu bar. Click Yes when prompted to begin the installation and configuration of the
Web Viewer Server.
2. For the Web Server to be installed in XP, the Windows Installation CD must be inside
the computer.
3. In Windows Vista/7, click Continue when prompted to provide administrator details (if
you are not logged as administrator to the computer) or to confirm installation of the
Web Viewer Server.
For more information on installing the Web Viewer Server, refer to Chapter 4: Software
for Workstation PCs.

Project Manager
6
Operating CIM Manager
This chapter describes how to operate the CIM Manager which is used for operating the
OpenCIM system and controlling production. The CIM Manager application is accessed
from the Project Manager, as described in Chapter 5, CIM Project Manager. It includes the
following sections:
Accessing the CIM Manager, describes how to access the CIM
Manager application.
CIM Manager Main Window, describes the main components of
the CIM Manager interface.
CIM Operational Modes, describes the operational modes of the
CIM Manager application.
CIM Manager Views, describes the various view screens in the CIM
Manager application for tracking the production process.
CIM Scheduler, introduces the CIM scheduler, enabling you to view
various production schedules.
Graphic Display and Tracking, introduces the Graphic Display
module displaying real-time, 3D animations of the operations being
performed in the CIM cell.

Accessing the CIM Manager
The CIM Manager is accessed from the Project Manager main window enabling the user to
centrally control all the activities of a selected OpenCIM cell.
To access the CIM Manager application:
From the Project Manager Main window, shown in Chapter 5: Project Manager, click CIM
Manager on the toolbar. The CIM Manager Main window is displayed, as shown in
CIM Manager Main Window in the following section.

CIM Manager Main Window
The CIM Manager Main window appears, as follows:
Figure 6-1: CIM Manager Main Window

The CIM Project Manager window, shown above, contains the following elements, each of
which is described in the sections that follow.
CIM Manager Menu Bar
CIM Manager Toolbar
Time Counter
PLC Status Bar
Viewing Area
Order View
Device View
Status Bar
CIM Manager Menu Bar

The CIM Manager Menu bar contains five menus, each of which is described in detail in the
sections that follow.
File Menu
The following table contains a brief description of each option in the File menu:
Option Description
Default Restores a predefined configuration of the storage from the backup database
Storage file.
Start Loads the production work order (A-Plan). Opens communication channel.
This sends a command to reset (INIT) all device drivers. The run arrow
turns blue and the stop button turns red, indicating that they are available for
use. The production plan will appear in the Program View screen.

Option Description
Run Starts executing the A-Plan. CIM production begins. The pause button turns
blue, indicating that it is available for use.
Continue Resumes operation after production has been paused.
Stop Stops production. It can be used as emergency button.
Modes Displays the Modes dialog box, as described in Modes Dialog Box.
Database Tool Displays the CIM Database browser. Recommended only for advanced
users.
Exit Exits the OpenCIM Manager application.
Utility Programs
The following table contains a brief description of each option in the Utility Programs menu:
Option Description
MRP Displays the CIM MRP window, enabling you to create a list of customers,
define the products ordered by each customer, and generate a manufacturing
order.
Machine Displays the CIM Machine Definition window enabling you to define the
Definition machines and the specific processes that the machines will perform.
Optimization Displays the CIM Optimization Manager enabling users to select machine
Definition queue algorithms and define their weight.
Part Definition Displays the CIM Part Definition window, enabling you to define the parts
that the CIM cell can manufature, including available parts and the parts
that need to be manufactured. These include: Supplied Parts, Product Parts
and Phantom Parts.
Performance Displays the CIM Performance Manager for viewing and analyzing
Analysis information generated form the manufacturing cycle.
Report Displays the CIM Report Part Definition window, enabling you to generate
Generator and print various reports from the database. These include, part definition
reports, machine definiton reports and more.
Scheduler Displays the CIM Scheduler window, enabling you to plan, coordinate and
Gantt track variuos production schedules. For further details refer to CIM
Scheduler.
Storage Displays the CIM Storage Manager window which manages and keeps track
Manager of parts in storage and informs the system of the part location.
Window
The following table contains a brief description of each option in the Windows menu:
Option Description
Device Displays the Device View window containing a lists of all the devices in the
CIM cell.
Event Displays the Event View window containing a list of events that will be
generated by OpenCIM simulation engine when Run is activated.
Leaf Displays the Leaf View window containing the production activities
occurring in the CIM cell.

Option Description
Log Displays the Log View window contains a list of all the messages that have
been sent and received by the CIM Manager.
Machine Displays the parts that are currently in the queue to the various machines for
Queue processing.
Order Displays the Order View window containing the current manufacturing
order information.
Pallet Displays the Pallet View window containing a list of the pallets in the CIM
cell and each pallet's current status.
Program Displays the Program View window, containing the A-Plan (the production
work order) of the CIM cell.
Storage Displays the Storage View window, containing the current location of parts
in the CIM cell.
Message Displays the Message History window, containing three types of messages:
History External Messages, Internal Messages, CIM Warnings.
View
The following table contains a brief description of each option in the View menu:
Option Description
Toolbar Shows or hides the CIM Manager toolbar.
Help
The following table contains a brief description of each option in the Help menu:
Option Description
About Displays the About OpenCIM Manager window contaning the current
software version information.
Help Displays the OpenCIM Online help.
Registration Displays the registration dialog box enabking you to perform various
registration options, such as obtain your software license from Intelitek's
website, or by e-mail, fax or phone.
CIM Manager Toolbar

The toolbar icons provide quick access to the most commonly used functions in the CIM
Manager window and appear as follows:
The following table contains a brief description of each option on the CIM Manager toolbar:
Option Description
Start: Loads the production work order (A-Plan). Opens communication
channel. This sends a command to reset (INIT) all device drivers. The
run arrow turns blue, and the stop button turns red, indicating that they
are available for use. The production plan will appear in the Program
View screen.

Option Description
Figure 6-2: Production Control Bar

Option Description
Run: Starts executing the A-Plan. CIM production begins. The pause
button turns blue, indicating that it is available for use.
Pause: Halts operation at any time; causes the CIM Manager to stop
sending commands to the device drivers and then wait until the Continue
button (which has turned red) is pressed. All device drivers complete the
current command.
Note
CIM devices do not stop immediately when you click the Pause button.
Each device will complete its current operation before it stops.
Continue:Resumes operation after production has been paused.
Stop: Stops production. It can be used as an emergency button.
Reset Storage: Restores a predefined configuration of the storage from

the backup database file.
CIM Modes: Displays the Modes dialog box, as described in Modes
Dialog Box.
Device View: Displays the Device View window containing information
referring to all the robots and machines in the CIM cell.
Event View: Displays the Event View dialog box that lists the events
generated by the OpenCIM simulation engine.
Leaf View: Displays the Leaf View window, providing a detailed
description of the production activities of the CIM cell.
Log View: Displays the Log View window that contains a log of all the
messages that have sent and recieved by the CIM Manager.
Pallet View: Displays the Pallet View window, containing the pallet
information in the CIM cell, such as descriptions, status and more.
Machine Queue View: Displays the Machine Queue View showing the
parts that are currently in the queue to the various machines for
processing.
Program View: Displays the Program View window, that contains a
copy of the A-Plan or production work order.
Storage View: Displays the Storage View window containing every
location defined in the CIM system.

Option Description
Message History: Displays the Message History dialog box with three
types of messages: External and Internal Messages and CIM Warnings.
CIM Manager Time Counter
The CIM time counter indicates the time elapsed since the onset of the production cycle.
PLC Status Bar
The PLC Status Bar, informs us whether or not the connection is active.
Viewing Area
The Viewing area enables you to monitor various aspects of the production cycle on a real-
time basis by selecting one of seven tab views. By default, the Graphic Display tab is
selected and the viewing area displays 3D graphic simulation of the CIM production cycle.
For further details on the tabs displayed in the Viewing area, refer to Graphic Display and
Tracking.
Order View
The Order View, located below the toolbar in the left portion of the window, displays data
regarding the order of parts and their production status.
Device View
The Device View, located below the toolbar in the right portion of the window, displays data
regarding the activity taking place in the devices during the production process.
Status Bar
The applications status bar, located at the bottom of the window, displays the status and
location of the application, such as the current operation mode and the location of the
WSO.ini file used by the manager.
Information Bar
The Information Bar displays general messages that occur during production, such as Order
is in progress and so on.

CIM Operational Modes
The CIM Manager can operate in the following modes:
Simulation Mode: The CIM Manager does not communicate with
device drivers. This mode does not require either hardware or device
drivers.
Real Mode: The CIM Manager communicates with all device
drivers, whether or not hardware is in use. This mode requires that all
device drivers which are needed for a specific application (for a
specific product order) be loaded, so that the CIM Manager can
transmit and receive messages.
Since the CIM Manager affects operation of the CIM cell hardware by communicating with
the device drivers (and not directly with the hardware), the CIM Manager can operate in real
mode even if the hardware has not been activated, or even if no hardware exists.
The CIM modes are described in the following table:
CIM Manager Device Driver Hardware
Mode of Operation
Simulation Not required. Not required
Real Mode All device drivers must be Not required.
loaded. Hardware may be activated, or it
may be simulated by the device
drivers, at some or all stations.
CIM Modes Dialog Box
The MODES Dialog Box is displayed by clicking the CIM Modes icon on the toolbar.
This dialog box enables you to define the current modes that are active in the CIM Manager,
such as, whether the CIM Manager is working in Real Mode or Simulation Mode, whether
the Web Viewer is activated and so on. The modes defined in the MODES dialog box are per
project.
Figure 6-3: Modes Dialog Box

CIM Mode Real Mode: In this mode there is message interchange between
Manager and Device Drivers.
Simulation Mode: The production runs on the
Manager. There is no message interchange
between any devices. You can set the
production speed for the simulation, where 1
is the slowest and 100 is the fastest.
Report to Scheduler as None: In this mode, the CIM Manager does not send messages
to the CIM Scheduler.
Planned: In this mode, the CIM Manager sends messages as
planned to the CIM Scheduler (generally, when CIM Manager is
operating in Simluation Mode).
Actual: In this mode, the CIM Manager sends actual messages
to the CIM Scheduler (generally, when CIM Manager is
operating in Real Mode).
Update Process Time No Duration update:Does not update the duration of any
process defined in Machine Definition.
Duration Update: Updates the duration of any process defined
in Machine Definition. The duration is the actual time that a
machine has taken to complete a process.
Web Viewer Specifies whether or not the web viewer is activated. Select the
required option, as follows:
Yes: Activates the Web Viewer.
No: Disables the Web Viewer.
For information on installing the web viewer server refer to
chapter 4.
For information on installing the web viewer client refer to
chapter 10.

Remote Graphic Display Specifies whether or not status messages are sent from the
devices in operation to the Graphic Display module so that the
display is updated accordingly.
Yes - Messages are sent to the Remote Graphic
Display.
No - Messages are not sent to the Remote Graphic
Display.
By default the Manager is configured to support only
one Remote Graphic Display.
To enable support for more than one Remote Graphic
Display:
1. Open Notepad by clicking Start | Accessories | Notepad.
2. Select File | Open and browse to [default system drive
(for example C:)]
Windows XP:
\Documents and Settings\All
Users\Documents\Intelitek\OpenCIM\Projects\<project
name>\setup\opencim.ini.
Windows Vista/7:
\Users\public\Documents\Intelitek\OpenCIM\Projects\
<project name>\setup\opencim.ini.
3. Find the NUMCIMULSOCKETS in the [networking]
key and change it to the required number of cim
simulations.
4. Click Save.
Note
If the Graphic Display is not activated on any PC, click No,
otherwise the manager will work very slowly.
Refer to Chapter 4: Software for Workstation PCs for
information on installing the Remote Graphic Display.
Once installed, the Remote Graphic Display can be launched via
the shortcut that is added to the Desktop.

To begin producing an order, do the following:
1. Start all OpenCIM device drivers by clicking on the Device
Driver Loader icon at each Station Manager PC. (Skip this step
if you intend to work in Simulation mode.)
Procedure
2. Select either Real Mode or Simulation Mode from the Modes
Starting Production
dialog box.
3. Reset the Storage by clicking the Refresh Storage icon.

4. In the CIM Manager, click the Blue button.
5. Click the Run button to start executing the production plan.
For safety reasons, when operating the CIM in Real Mode, you must use the actual
Warning! hardware EMERGENCY buttons to halt the system in an emergency.

Working in Simulation Mode
To operate the CIM cell in simulation mode, you must verify that the simulation mode is
selected in the CIM Manager.
To operate the CIM cell in simulation mode:
1. From the Project Manager application, select the required project and click CIM
Manager. The CIM Manager main window is displayed, as shown in CIM Manager
Main Window.
2. Select the Modes icon on the toolbar. The MODES dialog box is displayed.
3. Select Simulation Mode option, and if required adjust the simulated speed and define
additional options, as described in the CIM Modes Dialog Box, and click Save.
4. Verify that the Graphic Display tab is selected and click the Reset Storage button
on the CIM Manager toolbar.
5. If required, you can select Utility Programs | Scheduler Gantt to view the production
schedule.
6. Click the Start button to start, and click Run . The selected CIM Cell is now
running in simulation mode.
Working in Real Mode

To operate the CIM cell in real mode, you must verify that the real mode is selected in the
CIM Manager.
Before starting actual production, make sure you are in compliance with all the safety
measures detailed in Chapter 3, Safety.
Warning!
To operate the CIM Cell in real mode:

1. Remove any templates on the conveyor and at station buffers.
2. Remove any parts left at stations: in a robots gripper, in a machine and on storage
racks.
3. Load parts into the ASRS and into any feeders.
4. Turn on all hardware: PCs, controllers, CNC machines, etc.
5. Make sure all PCs have been activated.
6. From the PC of each Station Manager click the Loader WS1 icon (for example). The
CIM Device Driver Loader window is displayed.
7. In the Simulation column, select the mode in which you want to load the
device drivers by selecting or deselecting the column and click the Start
button.
8. At each station, home the robot and initialize all the equipment.
9. On the PC that contains the CIM Manager, perform the following:

1. From the Project Manager application, select the required project and click
CIM Manager. The CIM Manager main window is displayed, as shown in CIM
Manager Main Window.
2. Select the Modes icon on the toolbar. The MODES dialog box is displayed.
3. Select the Real Mode option, and if required define additional options, as
described in the CIM Modes Dialog Box, and then click Save.
4. If required, you can select Utility Programs | Scheduler Gantt to view the
production schedule.
5. Click the Start button to start, and click Run . The selected CIM Cell is
now running in real mode.
You can turn on OpenCIM workstation PCs and hardware in any order.
There is no mandatory boot-up sequence. You can also reboot a PC as long
Note
as it is not in the middle of an operation or communicating with the CIM
Manager. If you reset a PC, you do not need to reset other workstation PCs
connected to the OpenCIM network. When the PC boots up, its applications
will resume communication with other PCs on the OpenCIM network.

CIM Manager Views
During the manufacturing process, you can track production by looking at up to eight
different view screens, as follows:
Program View
Order View
Storage View
Device View
Log View
Machine Queue View
Pallet View
Leaf View (only after Run is pressed)
Event View (only after Run is pressed)
Message History
Click the appropriate icon on the toolbar to open the desired View screen, or select the
desired View from the alphabetical list in the Windows drop-down menu. Alternatively you
can replace the Graphic Display in the lower half of the Manager with the desired View
screen (with the exception of Log and Event) by clicking the appropriate tab.
Order View
The Order View is a copy of the Manufacturing Order. It is the most basic of the available
views.
Figure 6-4: Order View

The following is an explanation of each column in the Order View.
No. Line number from Manufacturing Order.
Part Name of part; as defined in Part Definition Form used in Manufacturing
Order. The grid containing the part name is progressively filled in red from
left to right, indicating the production status of the part which is being
manufactured.
Total Total number of parts to be produced, as defined in Manufacturing Order.
Done Number of parts that have been completed. Updated during production.
Fails Number of parts that have failed inspection. Updated during production.
In Process Number of parts that are being manufactured. Updated during production.

Storage View
The Storage View resembles the Location Status Report (see Chapter 5). This view is a
detailed listing of every location defined in the CIM system.
Figure 6-5: Storage View

The following is an explanation of each column in the Storage View.
Storage A list of all the locations in the CIM cell.
Index Indicates the exact location on a device which has more than one location
for a part. For example, the conveyor (CVN1) has three indices, one for
each station; the robot identified as ROBOT7 has only one index; the
ASRS1 has an index for each of its cells.
Status Graphic illustration of the contents of the location, as defined in the
PART and TEMPLATE columns. For example, EXPERTMILL1 has a
part named BOX.
PART Status of the specified location: either Empty or the Name of the part if it
exists at the location.
TEMPLATE Status of the specified location: either Empty or the ID of the template if
it exists at the location.
Device ID Device ID number defined in the Virtual CIM Setup (or assigned by the
CIM Manager during production).

Program View
The Program View is a copy of the A-Plan, or production work order. You can track the
current status of production by watching the Program View. This screen shows the
commands that the CIM Manager executes to produce an order. These commands are
executed in bottom-up order.
Figure 6-6: Program View

The following is an explanation of each column in the Program View screen.
Level This hierarchy number indicates the level in the Part Definition tree for
each ordered product. Operations at the same level can occur in parallel
(except an ONFAIL process).
Part Unique name used to identify the subpart currently under production.
Action The A-Plan command or user-defined process that the CIM Manager
executes to produce a part.
Subpart The part or object which the A-Plan action operates on.
Target The destination where this subpart is to be delivered.
Index (#) Parameters used by this command or process.
P1 Shows the current production status. The number of shaded Part columns
corresponds to the total number of parts ordered.
When a part is being produced, one of the following symbols appears at the
current stage of production:
Command sent, waiting for acknowledgment.
ON Device has begun processing this part (device driver has
responded with Start message).
OFF Device finished processing this part (device driver has
responded with Finish message).
The blue box indicates operation completed (device driver
has responded with End message).
WAIT CIM Manager is waiting for another operation to complete before
sending this command.

Device View
The Device View is a complete list of every robot and machine (including QC devices) in
the CIM cell and a description of the current action being performed by each.
Figure 6-7: Device View

The following is an explanation of each column in the Device View.
Device Name of the device or machine, as defined in the Virtual CIM Setup.
Status When a part is being produced, one of the following symbols appears at
the current stage of production:
RUN Command sent, waiting for acknowledgment.
Start Device has begun processing this part (device driver has
Finish Device finished processing this part (device driver has
End Device ended processing this part (device driver has responded with
End message).
Stop Device is ready for next command.
Load Device is loading the processing program from the Backup or the
Database.
Action The movement or operation command which is currently being executed
by the device. For robots, the action is commonly the placement of a part.
For machines, the action is usually the name of the process (as defined in
the Machine Definition form).
Station The number which identifies the workstation where the device is located.
ID The Device ID number, as defined in the Virtual CIM Setup.

Log View
The Log View is a transcript of the Leaf View. It details all messages which have been sent
and received by the CIM Manager.
Figure 6-8: Log View

You can control the amount of information that is displayed by editing the CIM Manager INI
file. By default, the system is set to display only IN PROCESS and DONE messages, which
allow you to see which commands have been sent and which have been executed.
Machine Queue View

The Machine Queue View displays the parts that are currently in the queue to the various
machines for processing.
Figure 6-9: Machine Queue View

The following is an explanation of the columns in the Machine Queue View:
Device. Lists the devices in the CIM cell.
Part ID (grade) Lists the ID and grade value of the color coded parts that are in
the queue to the specific device

Pallet View
The Pallet View is a complete list of every pallet in the CIM cell and a description of its
current status.
Figure 6-10: Pallet View

The following is an explanation of each column in the Pallet View.
No. Identification number of the pallet
Status Describes the status of:
Ready Pallet has not yet reached a station.
Pass Pallet is moving; has passed through the last station.
Stop Pallet has been stopped at a station to be unloaded.
Stop[Free] Pallet has been stopped at a station to be loaded.
Released Pallet has been released from a station.
To Station Number of the next workstation which pallet will reach. If pallet status is
(To St) Free, the destination is Station 999.
Part Name of part or subpart being carried by pallet.
Product Name of final product to which part belongs.
Template Identification number of the template being carried by the pallet.
Last Station Number of the last workstation which pallet has passed through.
(Last St)
Sim Place Simulated position; a sector location on the conveyor, as used in the
simulated graphic display.
Leaf View
The Leaf View provides a detailed description of the production activities of the CIM cell,
describing the current operation being performed on each item and the operation that will
immediately follow.

Figure 6-11: Leaf View
The following is an explanation of each column in the Leaf View.
Subpart of Part Name of the part and the name of the final product to which it belongs.
Action The action currently in progress (upper line) and the next process to be
>Next Process performed on the part. For example:
MILL2 = process defined in the Machine Definition form
BOX = part name.
EXPERTMILL1 = name of machine which will perform operation, as
defined in the Machine Definition form.
Status When a part is being produced, one of the following symbols appears at
the current stage of production:
Command sent, waiting for acknowledgment.
ON Device has begun processing this part (device driver has
OFF Device finished processing this part (device driver has
The blue box indicates operation completed (device
driver has responded with End message).
WAIT CIM Manager is waiting for another operation to
complete before sending this command.
Part ID An internal ID index for the part, generated by the CIM Manager.
Bar Code The ID number of the template which is carrying the part.
Leaf ID An internal ID index generated by the CIM Manager.
L1... Ln Additional information about other leaves.

Event View
The Event View is used only when the CIM Manager is operating in simulation mode; it
contains data only after the Run button is pressed.
The Event Queue is a list of events that will be generated by OpenCIMs simulation engine,
in order to ensure proper functioning of the simulation.
Figure 6-12: Event View

For example:
TIME = 135 (00:02:15) Indicates amount of time that has passed (135
seconds, or 2 minutes, 15 seconds) since the
Run button was pressed.
PLACE: Device start at 7 Indicates Robot 7 will send a Start message in
ROBOT7... 7 seconds and a Finish message in 15 seconds.
PLACE: Device finish at 15 ROBOT7
Message History
Figure 6-13: Message History Dialog Box

The Message History View allows you to view three types of messages:
External Messages: All messages that the CIM Manager sends to drivers via the TCP/IP
protocol and vice versa.
Internal Messages: Enables you to check CIM Manager setup parameters, e.g. path to
database files, path to utilities, simulation speed, etc.
CIM Warnings: All warnings issued by the CIM Manager. The last message is highlighted in
yellow. When a warning message is issued, the Message History dialog box opens. The most
frequently issued warning message is: Part not currently available. Update storage.

CIM Scheduler
The CIM Scheduler allows you to view various production schedules and determine the most
efficient one. The Scheduler is a Gantt utility that displays the exact timing and scheduling
of the different phases of production.
Figure 6-14: CIM Scheduler-Gantt Chart

The Scheduler can display two kinds of production schedules:
Planned: This schedule is normally produced and displayed when
the CIM Manager is operating in Simulation mode. Tracking mode
must be activated from the CIM Mode dialog box. For further details,
see CIM Modes Dialog Box.
Actual: This schedule is normally produced and displayed when the
CIM Manager is operating in Real mode. The Tracking mode is
deactivated.
The left side of the Scheduler screen is a textual description, while the right side is a graphic
representation (Gantt chart) of the production schedule.
Click and drag on the vertical lines in the table to increase and decrease column widths.

CIM Scheduler Toolbar and Menu Bar Options
The following table contains a brief description of each option in the CIM Scheduler toolbar
in addition to the corresponding menu bar item:
Online/Offline: When the Scheduler operates on-line, it displays data
from the CIM Manager. (No data is displayed until the CIM Manager
commences production.).
When the Scheduler operates off-line, it displays information from
Manager.Data is displayed as either Actual or Planned, depending on
the definition in the [Scheduler] section of the CIM Managers INI file.
Alternatively, select Display | Online/Offline from the CIM Scheduler
menu bar.
Sort by Machine: Shows the activities of machines and the parts they
process.
Alternatively, select Display | Sort by Machine from the CIM Scheduler
menu bar.
Shows the progress of parts, and the machines which process them.
Alternatively, you can also select Display | Sort by Part from the CIM
Scheduler menu bar
Enables you to clear the scheduler data .(Enabled in Online mode only.)
Alternatively, select File | Clean from the CIM Scheduler menu bar.
Displays the Load Data dialog box, enabling you to load additional
production schedules.(Enabled in Offline mode only.).
Alternatively, select File | Open from the CIM Scheduler menu bar.
Displays the Save as dialog box enabling you to save the current
production schedule.
Alternatively, select File | Save As from the CIM Scheduler menu bar.
Display
Options
Figure 6-15: Scheduler Display Options

Zoom: Value of time interval compression in Gantt chart display.
Show: Checked items are displayed in the textual display.

Creating a Planned Production Schedule
To create a planned production schedule, do the following:
1. Activate the CIM Manager.

2. From the Modes Dialog Box, activate the tracking mode.
Procedure 3. Reset storage.
4. Activate the CIM Scheduler.
Generating a Planned
Production Schedule 5. Click Start.
6. Click Run. Wait for the CIM Manager to complete an entire
production cycle.
Tip:
To speed up the simulation, change the value of the
simulation speed in Modes Dialog Box.
After you have generated a planned schedule, you can run the CIM Manager in real mode in
order to track and display the actual schedule, and see how it compares with the planned
schedule.

Graphic Display and Tracking
The OpenCIM Graphic Display and Tracking module provides a real-time 3D graphic
display of a working OpenCIM cell, displaying the movement of pallets on the conveyor
based on the status messages it receives as each pallet passes a conveyor station. The
Graphic Tracking module estimates the position of pallets as they travel between stations and
updates its display accordingly. It synchronizes its display with the actual pallet position
every time a pallet passes a conveyor station.
Status Messages
When a device performs an operation on the part, its device driver transmits status messages
to the CIM Manager reporting the outcome The CIM Manager forwards these messages to
the Graphic Tracking module, which then updates its display accordingly.
Examples of these messages include:
Command Response Messages: A device driver responding to a
command sent from the CIM Manager, or a device driver responding
to a command sent from another device driver (such as, a CNC
device driver responding to commands sent by a robots ACL or
Scorbase device driver to open and close its door).
Pass Messages: The PLC device driver sending a Pass message
indicating that a pallet that is not needed at this station has just gone
by. Pass messages are generated only to allow the Graphic Tracking
module to update its conveyor display, and are not used by the CIM
Manager or any other CIM entity.
Updating the Display

The CIM Manager relays the status messages to the Graphic Tracking module, which then
updates its display accordingly. The display can show the following examples:
Parts, as they move from device to device (such as, a robot picking
up a part from a template and putting it in a CNC machine).
Pallets, moving around the conveyor.
The screen display includes detailed representations of station elements such as computers,
controllers, CNC machines, and robots as shown in the following figure. This module
updates its display in response to real-time status messages emanating from the CIM
Manager and active device drivers.
The Graphic Tracking PC can be used in the following modes:
Real Time Mode, enabling you to observe the flow of parts around
the CIM cell.
Simulation Mode, enabling you to observe the results of different
production strategies on-screen without actually operating the CIM
equipment.

The graphic display module appears in the Graphic Display tab, as follows:
Figure 6-16: Graphic Display on Manager

Graphic Display Toolbar
The following table contains a brief description of each option in the Graphic Display
toolbar:
Option Description
Maximize/Restore: Enables you to toggle between maximizing and
restoring the Graphic Display tab.
Redirect Camera: Defines the position that will be in the center of the
image.
Follow Me Camera: Enables you to focus on the location of specific part
during a production cycle.
Drag Scene: Enables you to pan the CIM cell left, right, up and down.
Top View: Places the camera on top of the cell at the center of the image
Save Camera Position: Saves the current position of the graphic dispay
screen until the next time you enter the CIM Manager application.
Toolbar View: Displays or hides the IDs of the objects, templates, parts,
and pallets, each of which is described below.
Show Name:Displays the names of the objects that currently exist in the
CIM cell.
Show ID:Displays the object IDs that exist in the current CIM cell.
Show Pallets: Displays the pallet numbers that are currently on the
conveyer.
Show Templates: Displays the IDs opf the templates in the CIM cell.
Show Parts: Displays the IDs of the parts in the CIM cell.
In addition, the following options enable you to change the view of the CIM cell:
Zoom In/Zoom Out: Zooms in and out of the image by pressing the
right mouse button and moving it forward or backward.
Rotate the Image: Rotates the view of the image by pressing the
right mouse button and moving it to the right/left.
Moving the Camera Up/Down: Use the windows scroll bar to
adjust the viewing angle of the image.
Alternatively, the viewing angle can also be adjusted by scrolling the mouse wheel.
The Graphic Display of a working OpenCIM cell is displayed in the CIM Manager window
and it can also be displayed on another PC (WebViewer application and Remote Graphic
Display.) It is possible to display three different 3D views at the same time on the same
screen as shown in Figure 6-17.

Figure 6-17: Graphic Display
Tracking the Production Process

The following procedure describes how to graphically track the production in the OpenCIM
system:
1. Launch Project Manager . To do so, select the project and click the
CIM Manager icon in the tool bar.

Procedure 2. Click the Blue Load button. Click Run (Blue arrow).
Graphic Tracking of 3. Now you can observe the operations performed in the CIM cell in
Production both Graphic Displays: the Manager and in the 3D views.

Manipulating the Graphic Display Views
The Graphic Display module offers two types of views, an overhead view and an elevated
side view. This procedure describes how to manipulate these views according to your
requirements.
Note When the Simulation window opens, it always displays the view that was displayed
when you last closed either the Graphic Display or the Virtual CIM Setup window.
To manipulate the views:
1. To change the angle of the overhead scene, place the cursor on the
vertical scroll bar and drag it up and down. (It is recommended that
you click on the vertical scroll bar up and down arrows.)
Procedure
Manipulating the 2. To rotate the scene, place the cursor anywhere on the screen and:
Graphic Display Click the right mouse button and drag to the right to rotate the
display counterclockwise.
Click the right mouse button and drag to the left to rotate the
display clockwise.
3. To zoom the scene, place the cursor anywhere on the screen and:
Click the right mouse button and drag up to zoom in.
Click the right mouse button and drag down to zoom out.
Changing the Focus of the Graphic Display

The following procedure describes how to change the focus of the Graphic Display.
To change the focus of the Graphic Display:
1. Click on View | Redirect Camera.

2. Click any object in the scene. It now becomes the center point for the
Procedure display manipulation. The view changes to an overhead scene (if it is
Changing the Focus of not already), which you can now manipulate, as described above.
the Graphic Display
The Text menu allows you to select the kind of captions you want to include in the graphic
display. Only one kind of text can be selected at a time.
None No text. Select None to remove the currently displayed caption. You may
then select another kind of text. (Note that there is no checkmark in the
menu to indicate your selection.)
Name Name of machines and devices.
Ext. ID External ID number, as defined in the Virtual CIM Setup.
Pallets Displays the ID number of the pallets.
Templates Displays the ID number of the templates.
Parts Displays the ID number of the parts.
The File menu offers the following options:
Open Loads a new graphic CIM cell. Do not use.
Exit Quits the Graphic Display module.

7
CIM Manager Utility
Programs
This chapter describes the CIM Utility Programs which are used for preparing the OpenCIM
system for production. These programs are an integral part of the CIM Manager software and
can be accessed from the Utility Programs menu of the CIM Manager menu bar. The Utility
Programs menu includes the following:
Machine and Process Definitions, introduces the CIM Machine
Definition window, enabling you to define the machines and
processes in OpenCIM.
Part Definition, introduces the CIM Part Definition window,
enabling you to define the parts that OpenCIM can manufacture.
Storage Definition, introduces the CIM Storage Manager, enabling
you to track the parts in storage.
MRP (Material Requirements Planning), introduces the CIM MRP
window, enabling you to create customer lists and product orders.
Optimization, introduces the CIM Optimization Definition window
for defining queue algorithms as well as additional optimization
methods used in OpenCIM.
Performance Analysis, introduces the CIM Performance Analysis
window for viewing and analyzing information generated form the
manufacturing cycle.
Reports, introduces the CIM Report Generator enabling you to
generate predefined or customized reports for viewing and printing.
You can use these programs to view some existing sample definitions to assist you in making
your own.
As you read through this chapter, it is recommended that you perform the Procedures.
These tutorials will help you become familiar with using the OpenCIM software.
The examples shown in this manual are based on the sample project TUTORIAL_SAMPLE
which is located in the projects archive list in the project Manager. (For details on
transferring a project from Archive to User refer to Chapter 5).

CIM Manager Utility Programs
Machine and Process Definitions
When you define a machine, you actually define the specific process a machine will perform.
Machine names are usually predefined in the Virtual CIM Setup and only need to be selected
from the Machine Name drop-down list.
The process name enables the CIM Manager to determine which machine is capable of
performing the specific work required to produce a part (as defined in the Process field in the
Part Process Table in the Part Definition form). If two machines that are capable of
performing the specific process are available, the CIM Manager tries to optimize the use of
these two machines to complete the process (see Optimization in this chapter).
The Machine Definition form lets you view any machine that has been defined for the
system. You can define new or modify existing processes for the machine to perform. A
machine record contains the machine name and one or more defined processes (process
record). Each field and the control buttons associated with this form are described in detail in
this section.
The CIM Machine Definition window displayed below is accessed by from the CIM
Manager Main Window, by selecting Utility Programs | Machine Definition from the
Menu bar.
Figure 7-1: Machine and Process Definition Form

Machine Definition Window
Main Menu
Option Description
File Contains these file options: Save All, Save Selected Machine, Print
Machine Report, Exit (from Machine Definition screen). The first three
options also appear as tool buttons in the Toolbar (see below).
Edit Contains the following options for editing rows: Insert Before, Insert
After, Delete Row. The rows inserted are copies of the original row,
enabling you to edit the content.
You can also access these options by right-clicking the process list cell
you want to edit.
Help On-line help.
Toolbar
Option Description
Saves all machine records to disk.
Saves the selected machine record to disk.
Automatically resizes the columns to accommodate long values (when the

window is maximized).
Print machine report.
Select a machine from the machine name drop-down list. The names that
appear in the list are defined in the Virtual CIM Setup.

Machine Process Table
The data fields above the table are also displayed as columns in the table. Their descriptions
are provided below.
Option Description
Machine A descriptive name which uniquely identifies the machine. You can
Name edit/examine the record for a specific machine by selecting that machine
name from the drop-down list in the toolbar. All machines that are defined
in the Virtual CIM Setup appear in this list.
Process The name of a production process that can be performed by this machine. A
Process Name can only be used once for a given machine.
The name should be easily recognizable to CIM users and may contain the
characters AZ, 09 and underscore ( _ ), but no spaces.
This Process Name is assigned to a part in the Part Definition form (in the
Process field of the Part Processes Table).
Assigning a process to a part instead of a machine can have advantages
when there are two or more machines capable of performing the same
process. Having more than one machine capable of performing a given
process allows the CIM Manager to select the machine which can process a
part most efficiently and redirect production if one machine fails.
Note
For different machines that can perform the same process, you should enter
the same process name. Likewise, do NOT use the same process name to
refer to processes on different machines which do not perform the same
operation on the same part.
The following reserved words cannot be used as Process names:
ALLOC GET PACK
ASSEMBLY GET_FIX PLACE
BASE MAKE PROCESS
CNC MOVE QC
DELIVER NEXT RENAME
END_ASSEMBLY NOP TARGET
FREE ONFAIL TRANSFER

Option Description
File A file containing the G-code program or other program associated
with this process. This file name can include a valid directory path to
a file. If no path is specified, the CIM Manager expects to find this
file in the current working directory associated with the device
driver for this machine.
A file can contain one machine control program. Different machines
that perform the same process will have their respective control
programs stored in different files.
Program The name of the machine control program associated with the
process being defined. This Program Name is used by an ACL
controller which is operating a machine.
Fail(%) Your estimate of the number of rejected parts that will result when
this process is run on this machine (0 - 100%). The CIM Manager
takes this value into consideration only when simulating a quality
control process.
Duration The number of minutes this process takes to produce one part. The
CIM Manager takes this value into consideration when choosing
among multiple machines that can run the same process. Format is
hh:mm:ss
Parameters This string of arguments is passed to a machine control program

associated with this process.
WS The workstation in which the machine is placed. Automatically
displayed by the system (as defined in the Virtual CIM Setup).
Machine Type The type of machine selected. Automatically displayed by the
system (as defined in the Virtual CIM Setup).
Action Type A label that defines the characteristics associated with a process. One
of these Action Types (in the data field above the table) is selected by
default:
Action Type Description
Assembly A process which involves the assembly of two or
more subparts.
QC A process involving a test that reports a Pass/Fail
result to the CIM Manager. If the result is Fail, the
rejected part is redone. A quality control process
requires an ONFAIL entry in the Part Processes
table in the Part Definition form see Part
Definition below.
CNC A process which has G-code program(s)
associated with it. The CIM Manager downloads
the G-code file specified in the File field to the
CNC machine (unless this file is already resident
in the CNC machine).
Process A basic machine operation which does not
require any special action beforehand or
afterwards. Runs the ACL program specified in
the Program field.

Option Description
Place A robot operation used for non-standard
operations performed by a robot. The File and
Program fields will be blank.
Robot- controlled Specifies if a robot is needed to perform the process. For example,
if a welding action is performed by a robot, specifying YES
signals the CIM Manager that the robot is in use and is not free to
perform another operation. This option is available only if the
machine selected can use a robot to perform a task, and if the
Action Type is Process.
Cost per Hour Estimated hourly cost to run this machine. The CIM Manager uses
this as one of the criteria in order to decide on the optimum
production method.
List of Preloaded Programs

Tasks are control programs that can be downloaded to a machine (e.g., G-code to a CNC
machine). The CIM manager keeps track of which programs currently reside in a machines
memory. If a certain process requires a machine control program that is not resident, the
CIM Manager instructs the CNC device driver to download it to the machine.
Option Description
Max Preloaded The number of control programs that can reside in a machines
Programs memory at one time. Once this number is exceeded, the CIM
Manager begins overwriting programs in the machines memory
when it needs to download a new program.
List of Preloaded The current status of control programs that are loaded in the
Programs machines memory. This box is for information purposes only; it
cannot be used to change the programs residing in a machine.

How to Define a Machine
The procedures presented below refer to an OpenCIM sample application for producing a
simple, covered box (product). When defining the process for the covered box, two
processes need to be defined: CNC milling and assembly.
These procedures represent a simplified example. When defining more complicated applications,
entries to other fields will also be required.
Note
A. Defining the Milling Process

1. In the Machine Definition form, select EXPERTMILL1 from the Machine
Procedure Name drop-down list; this is the name for the milling machine, as defined in
the Virtual CIM Setup. The MILL1 record becomes the current record and
appears in green in the Machine Process Table. The record contains the
process(es) defined for the machine. The workstation is shown as WS3, the
machine type as M-MACHINE, the action type as CNC, and Robot-
controlled as No and gray.
2. In the Process column, type in the Process Name MILL2. (You will need to
make sureeither now or laterthat MILL2 appears in the Process field
in the Part Process Table in the Part Definition form).
3. In the File column, type in GCODE.NC, for example, as the name of the G-
code program file that contains the instructions for this type of process.
4. In the Duration column, type in the amount of time it takes the mill to
perform this operation, e.g., thirty seconds.
5. Your screen should now look like this:
Figure 7-2: CIM Machine Definition Defining the Milling Process


6. Click to save the currently displayed information to the database. You
can now generate and view a Machine or Process Report by using the
Procedure Report Program.
7. Continue with the procedure Defining the Assembly to define the other
process which is required to produce the covered box
Note: The assembly operation is usually performed by a jig device (such as a

pneumatic jig) not a machine.
B. Defining the Assembly Process
1. In the Machine Definition form, select JIG1, from the Machine Name drop-
down list; this is the name of the device that performs assembly operations,
as defined in the Virtual CIM Setup. The JIG1 record becomes the current
record and appears in green in the Machine Process Table. The workstation
is shown as WS3, the machine type as J-JIG, the action type as
ASSEMBLY, and Robot-controlled as NO and gray.
2. In the Process column, type in the Process Name ASSY. (You will need to
make sureeither now or laterthat ASSY appears in the Process field in
the Part Process Table in the Part Definition form.)
3. In the Duration column, type in the amount of time it takes the mill to
perform this operation, e.g., 12 seconds.
4. Your screen should now look like this:
Figure 7-3: CIM Machine Definition Defining the Assembly Process
5. Click to save the information to the database.

You can now generate and view a Machine or Process Report by using the
Report Program.

Part Definition
A product is manufactured from a group of subparts (bill of materials) that are put together
according to a specified set of machine processes. Starting with a set of raw materials
(supplied parts), you define parts at the intermediate stages of production required to
assemble a final product.
The Part Definition screen, or form, allows you to enter the bill of materials and the
associated production processes used to produce a part. Using the Part Definition form, you
can either:
Modify/view the production process for an existing product.
Describe the production process for a new product.
Defining a new product involves the following steps:
Drawing a part definition tree.
Setting up all machine processes necessary to produce a product and
all its subparts.
Determining what new template designs are required to handle all the
parts involved and assign these designs template ID numbers.
Determining the types of racks that can hold each subpart.
The Part Definition form for Product (or Phantom) parts lets you create, view, or modify the
current part (either a product or its subparts). A part record contains all the fields shown on
the Part Definition form below. Each field and the control buttons associated with this form
are described in detail in this section.
Figure 7-4: Part Definition Form for Product or Phantom Part
If you define the part as Supplied, the Part Process table will be replaced by a section
containing data regarding the supplier and supplied material, as shown below:

Figure 7-5: Part Definition Form for Supplied Part

Part Definition Form
Main Menu
Option Description
File Contains these file options: New Part, Save Current Part, Save All,
Print, Exit (from Part Definition screen). The first five options also
appear as tool buttons in the Toolbar (see below).
Edit Contains these row and part editing options: Insert Before, Insert After,
Copy Part, Paste Part, Delete Row, Delete Part. You can also access
these options by right-clicking the process list cell you want to edit.
Help On-line help.
Toolbar
Option Description
Defines new part
Saves all part records to database.
Saves the selected part record to database.
Automatically resizes the columns to accommodate long values (when

the window is maximized).
Prints part report.
Selects a predefined part from the part name drop-down list.
Selects a predefined part ID from the part ID drop-down list.
Information Bar
Option Description
Defines the template type (01-99) whose pin arrangement can
accommodate the selected part.
Defines the types of racks/feeders that are capable of
accomodating the selected part.
Defines the color of the parts that can be viewed on the
conveyer. You can define a different color for each part. The
part color will change after the work on the part is completed.
Note:
The color will not be changed for custom parts which are
provided in the OpenCIM installation.

Option Description
Defines a part shape from either the list of supplied or
previously added shape parts, or by browsing to a new user
defined part.
When a new 3D file is added by browsing, the file is added to
the project directory for example:
In Windows XP: [default
system drive (for example
C:)]\Documents and
Settings\All
Users\Documents\Intelitek\Op
enCIM\Projects\
TUTORIAL_SAMPLE\CIM_
CUSTOM_parts.
In Windows Vista/7: [default
system drive (for example
C:)]\Users\Public\Documents\I
ntelitek\OpenCIM\Projects\
TUTORIAL_SAMPLE\CIM_
CUSTOM_parts.
Designing User Parts and Objects

Users can add other parts and objects over the existing ones that are provided with the
installation of the software.
There are two stage to creating new parts and objects.
Creating Parts and Objects
Adding Parts and Objects to OpenCIM Projects
Creating Parts and Objects

There are three ways to create new parts and objects:
Modify an Existing User Part File
Create a New Part/Object File
Import a CAD File
Modify an Existing User Part File

Existing user parts that are provided with the installation may be modified to suit the
requirements of the user.
To modify an existing user part:
1. Open the CIM_CUSTOM_PARTS folder located in the following directory:
Windows XP: [default system drive (for example C:)]\Documents And
Settings\All Users\Documents\ Intelitek\OpenCIM\CIM_CUSTOM_parts
Windows Vista/7: [default system drive (for example C:)]\Users\Public\Public
Documents\Intelitek\OpenCIM\CIM_CUSTOM_parts.
2. Using a text editor that saves files in plain ASCII format, such as Notepad, open one of
the existing user part files in the directory. Below is an example of a part file.
ModelBegin
TransformBegin
Color 0.0 1.0 1.0
Surface 0.4 0.3 0.2

Opacity 1.000000
LightSampling Facet
GeometrySampling Solid
TextureModes Lit
Texture NULL
ClumpBegin
Translate 0.0 0.0251 0.0
Tag 1
Block 0.05 0.05 0.05
ClumpBegin
Tag 2001
Color 1 0 0
Opacity 1
Block 0.03 0.02 0.07
ClumpEnd
TransformEnd
ModelEnd
3. Edit the file to modify the part. (Refer to the documentation provided in Program
files\intelitek\opencim\sources\Graphics\RW\Documentation for details on RWX
commands).
See the Adding Parts and Objects to OpenCIM Projects section for details on adding the file
to OpenCIM project(s).
Create a New Part/Object File

To create your own user part and user object files:
1. Open a text editor that saves files in plain ASCII text, such as Notepad.
2. Write the program to create your own part. (Refer to the documentation provided in
Program files\intelitek\opencim\sources\Graphics\ RW\Documentation for details on
RWX commands).
See the Adding Parts and Objects to OpenCIM Projects for details on adding the file to
OpenCIM project(s).
Import a CAD File

You can create a 3D object in a CAD program, and import it to CIM Part Definition.
To import a CAD file:
1. Create a file in any CAD program and save it as a *.dxf or *.3dc file.
2. Use the RW3DCONV converter to convert the file to RWX format. This converter is
provided with the installation of OpenCIM, and is located in the following directory:
program: files\intelitek\opencim\sources\Graphics\RW\ converter.
Ensure that there are no more than 1000 polygons in the CAD file.
Note
See the next section for details on adding the file to OpenCIM an project(s).
For more information on RWX files, refer to the RWX help file which is provided with the
OpenCIM installation, and is located in the following directory: Program
files\intelitek\opencim\sources\Graphics\RW\Documentation.
Adding Parts and Objects to OpenCIM Projects

Parts and objects can be added to a single project only, or to all projects, such that they will
appear in the 3D file are drop-down menu of every project in OpenCIM.
To add the part or object to a single project:

1. Save the file as a .rwx file.
2. Open the Part Definition utility by selecting Utility Programs | Part Definition from
the OpenCIM Project Manager.
3. Click Browse in the 3d File area at the bottom right of the window.
4. Browse to the location of the file that you saved and click OK. The part is added into
the project, and appears in the 3D File drop-down menu. A copy of the file is added to
the following directory:
XP: [default system drive (for example C:)]\Documents And Settings\All
Users\Documents\ Intelitek\OpenCIM\
TUTORIAL_SAMPLE\CIM_CUSTOM_parts.
Vista/7: [default system drive (for example
C:)]\Users\Public\Documents\Intelitek\OpenCIM\Projects\TUTORIAL_SAMPL
E\CIM_CUSTOM_parts.
To add the file to all projects, save the file as a .rwx file in the following directory:
XP: [default system drive (for example C:)]\Documents And Settings\All
Users\Documents\ Intelitek\OpenCIM\CIM_CUSTOM_parts
Vista/7: [default system drive (for example C:)]\Users\Public\Public
Documents\Intelitek\OpenCIM\CIM_CUSTOM_parts.

Part Table
Option Description
Part Type Select one of the following types for this part:
Product A part that can be ordered from the CIM. The
final part at the top of the part definition tree
is always defined as a product. Part is the
product that is produced by the CIM system.
In some industrial software, the term
MAKE is often used to refer to the product.
Supplied A part received from an outside source, i.e. a
part not produced by the CIM, therefore it
does not require a process definition. Supplied
parts do not contain any entries in their Part
Process tables. A supplied part is found only
at the bottom of the Part Definition tree. In
some industrial software, the term BUY is
often used to refer to the supplied part.
Phantom A part or subpart which has failed QC.
This definition allows the CIM
Manager to issue instructions on how
to handle a rejected part. Phantom
parts cannot be ordered.
Product Part Data

Option Description
Part Name A string which uniquely identifies this part (i.e. two parts cannot have the
same name). The name should be easily recognizable to CIM users. The
string may contain the characters AZ, 09 and underscore ( _ ), but no
spaces.
Part ID A numeric value (1 999) which uniquely identifies this part (i.e. two parts
cannot have the same ID). This Part ID can be used with devices which
require a numeric part identifier. For example, the ACL controller uses the
Part ID to activate the appropriate control program to handle this part.
Subpart The name of a material used to produce the current part.

Option Description
A subpart must be defined in its own Part Definition record. A subpart can
either be a raw material (i.e. a Supplied Part) or a part produced by the
CIM (i.e. a Phantom Part or a Product).
Some rows in the Part Process table require a Subpart name while others
do not. A Subpart name is required in the following circumstances:
A Subpart name is required in row 1 of the Subpart column.
A Subpart name is required for each part that is included in an
assembly.
A Phantom Subpart name is required after each quality control
test in order to associate a name with the ONFAIL exception
handler.
After the first row, a subpart name is not required if the process being per-
formed operates on the same part that was listed in the previous row. For
example, the first row could specify the name of a cube that is to be
machined into a box. The second row specifies a process that drills a hole
in the box. In this case, the subpart field of the second row would be blank
because the drill operates on the same subpart specified in row one.
If you need more than one of a subpart, add a separate row to the Part
Process table for each unit.
A circular definition error will result if you enter a subpart name that
matches the name of the part being defined (i.e. Subpart = Part). This error
will also occur if any of the subparts in turn contain a subpart that matches
the Part Name being defined.
Process Enter the name of a production process that has been defined in the
Process field of the Machine Definition screen.
If this process exists on more than one machine, the CIM Manager selects
the machine to use according to its production strategy (e.g. minimize
cost, minimize production time, etc.).
Parameters The Parameters field specifies how to carry out this process when it is
performed for the current part.
For quality control devices, the parameter string is used to specify the type of QC test and
the range of acceptable values.
For a machine that performs assembly operations, the parameter string specifies where to put
the part that is being added to the assembly. If this target location contains compartments,
you can add an optional index for the compartment number.
The table below details how parameters are used by several devices:
Device Example Description Note
ROBOT- 1, 4 type of test, If maximum value is
VISIONpro minimum value, omitted, the minimum
[maximum value] value represents the
single acceptable value.

Device Example Description Note
Laser Scan 1,150, type of test, If maximum value is
Meter 160 minimum value, omitted, the minimum
[maximum value] value represents the
single acceptable value
(with a tolerance of
5%).
Assembly BOX, 2 target location, Places subpart assembly
Machine [target index] BOX in location #2.
The following system variables can be used in the Process definition.
Variable Description
$PARTID Part ID as defined in the Part Definition form.
$TEMPLATEID The Template ID (six digits) defined in the Storage Definition
form.
$TEMPLATETYPE The Template Type (two digits) defined in the Storage
Definition form.
$PRIORITY The Priority defined in the Manufacturing Order.
$DURATION The Duration defined in the Machine Definition form.
Supplied Part Data

When you select Supplied as the Part Type, the Part Process table is replaced by a form that
allows you to define the supplied part.
Option Description
Part Name A string which uniquely identifies this part (i.e. two parts cannot have the
same name). The name should be easily recognizable to CIM users.
The string may contain the characters AZ, 09 and underscore (_), but no
spaces.
Part ID A numeric value (1 999) which uniquely identifies this part (i.e. two parts
cannot have the same ID). This Part ID can be used with devices that require
a numeric part identifier. For example, the ACL controller uses the Part ID
to activate the appropriate control program to handle this part.
Supplier The name of the supplier from whom the raw material / supplied part is
Name purchased.
Supplier The suppliers catalog number for the raw material / supplied part.
Catalog
Number
Minimum The smallest quantity of this part which can be purchased from the supplier
Order at a time.
Safety Stock The number of units of this material / part required by the CIM cell to
guarantee production without interruption.
Cost The cost of one unit of the raw material / supplied part.
Supply time The amount of time it takes the supplier to deliver this material / part to the
(days) CIM cell.

Option Description
Description A description of the part being defined that explains what it is and where it
is to be used.
Template The Template type (01 99) whose pin arrangement can accommodate this
Type part.
Rack/ If this part is to be stored in a feeder, specify which types of feeder are
Feeder Types capable of accommodating this part (Feeder Type > 100). Feeder types are
defined in the Virtual CIM Setup. You can specify multiple feeder types in
this field; each one separated by a comma (e.g. 101, 102, 103).
Selections are made by choosing from a drop-down list or by typing in the
entry.
Similarly, if this part is to be stored temporarily in a rack during processing,
specify which types of racks are capable of accommodating this part. See
Rack Type definition above.
How to Define a Part
In order to define a part, it is important that you understand the entire operation. A part is
only the starting point. This part (supplied, raw material) moves within the CIM system
according to a predefined path, the part is processed (with another part) and the product is
then created.
In order to define a part, you need to:
Define the supplied material(s)
Define the process that must be performed on the material(s)
Define how to assemble the parts (processed and supplied materials)
These concepts can be better explained by referring back to the OpenCIM sample application
of producing a simple, covered box from a small, solid cube and a matching cover. From
this example we can determine that:
Raw Material #1 Box
Raw Material #2 Cover
Product Covered_Box

1. In the Part Type form, select Supplied parts.
2. From Main Menu select FILE | NEW PART or click the New button on

Procedure
the toolbar.
Defining the Raw 3. In the Part Name field, select BOX (the solid cube from which the box will
Material(s) be milled) from the drop-down list.
4. In the Part ID field, enter a unique ID for this raw material; for example, 1.
5. In the Template Type field, enter an identifying number for the type of
template which will be dedicated to carrying this part; e.g., 01. (This data
will be read and used by the Storage Definition program.)
6. In the Rack/Feeder Type, select the type of rack that will be used to hold this
part at the workstation; e.g., Rack 201. If a rack or a feeder is not used,
leave the field blank.
The remaining fields are not required to enable production; they are used to
provide statistical data.
7. Click Save to save the part.
8. Click New and repeat steps #2 6 for the other raw material which will be
used in the assembly: COVER. Your screen should now look like this:
Figure 7-6: Part Definition Form for Supplied Parts Defining a Part
9. Continue on to the procedure Defining the Product as described below.
When to Define a Subpart (New Part)

Use the following criteria to help determine when to create a subpart at an intermediate stage
of production (by entering a name in the Subpart field):
Define a new subpart if it is needed in the production of other
products.
Define a new subpart to enable an order to be placed for this part
(e.g. for use as a spare part).
Define a new subpart if it requires a different template type.
Define a new subpart if it is to be used in the assembly of some other
product.
How to Define an Assembly Process
An assembled part (assembly) always has at least two rows. The Subpart name specified in
row 1 is referred to as the original material.
The assembly is always performed at or by a machine (such as a pneumatic vise), which is
often defined as JIG in the list of Machine Names in the Machine Definition form.
The process for the subpart in the second row must be defined in the Machine Definition
form as Action Type Assembly.

1. In the Part Type form, select Product parts.

2. From Main Menu select File | New Part or click the New button on the
Procedure toolbar.
Defining the Product 3. In the Part Name field, enter COVERED_BOX (the name of the product).
4. In the Part ID field, enter a unique ID for this product; for example, 3 or
accept the default ID number.
5. Select the Subpart cell. Choose BOX from the drop-down list and type
MILL2 as the Process.
6. Add a new process row by right-clicking on any cell into the current row
and choose Insert After from the edit menu. In the second row in subpart
field, choose COVER from drop down list and type ASSY as the Process.
7. In the Template Type field, enter an identifying number for the type of
template which will be dedicated to carrying this part; e.g., 01. (This data
will be read and used by the Storage Definition program.)
8. It is not necessary to specify a Rack/Feeder type for the final product.
Your screen should now look like this:
Figure 7-7: Part Definition Form for Product Parts
9. Click to save .
10. You can now generate and view a Part Definition Report by using the
Report Program.
The above listed procedures represent a simplified example. When defining more
complicated parts it may be necessary to:
Note
Enter products in the Subpart column of the Part Process Table.
Use only predefined process names in the Process column of the Part
Process Table.
Add parameters.

How to Define Quality Control Processes
Whenever you include a quality control process in a Part Definition, you must make
provisions for how to handle the rejected part if it fails the quality control test by defining a
special part (quality control exception handler). While a rejected part is being processed, the
CIM Manager begins producing a replacement part.
Figure 7-8: Including a Quality Control Check in a Part Definition
Table Entry Explanation

PROCESS | VIEWFLEX Quality Control Test
SUBPART | REJECTED Quality Control Test Failed (exception handler)
PROCESS | SCREWING Quality Control Test Passed (continue from here)
The following procedure details the steps involved in handling rejected parts:
1. In the Process column of the Part Process table in the Part Definition

form, enter a quality control test, i.e., a process whose Action Type is
Procedure defined as QC in the Machine Definition form, for example: Viewflex.
Setting Up the QC 2. In the next row of the table, in the Process column, enter ONFAIL.
Exception Handler 3. In the Subpart column of this row, enter a unique name for the part,
e.g. Rejected, and make sure it has been defined as a Phantom part.
4. Click Save when you are finished.
5. For all subsequent rows in the Part Process table, assume that the part
has passed the quality control test. Continue defining the normal
production steps for this part.

Storage Definition
The CIM Manager must keep track of which parts are in storage and which templates are
available to move these parts from station to station on the conveyer. You can use the
Storage Definition form to:
Update the contents (part and/or template) of storage locations.
Create/modify template codes.
Figure 7-9: CIM Storage Manager Window
Storage Manager Form

The Storage Manager administrates all types of materials used in an OpenCIM cell. There
are three types of Storage: ASRS (automated storage and retrieval system), Rack and Feeder.
Option Description
ASRS The ASRS is the main storage device in an OpenCIM cell. It serves as a
warehouse for parts in various stages of production. ASRS cells contain
templates, either empty or loaded with parts.
Rack This type of storage can contain parts in any stage of production. Templates
cannot be stored in racks.
Feeder Contains raw material only.
Main Menu
Option Description
File Contains these file options: Save to DataBase, Reset Storage, Create
Default Storage, Clear Temporary Storage, Initialize Storage, Exit (from
Storage Manager screen). These options also appear as tool buttons in the
Toolbar (see below).
Edit Contains these part editing options: Add Part to Storage, Delete Part from
Storage.
Help On-line help.
Toolbar
Option Description
Saves the current Storage configuration to the database.

Adds a new row in the ASRS block. This is used when the location of the
part within the ASRS is not important.
Deletes a row from the ASRS block.
Resets storage or default storage. Restores a predefined configuration of the

storage from the backup database file.
Creates default storage. Creates a backup database file of the current storage
configuration.
Clears temporary storage. Removes any part or template from Temporary
Storage devices.
Initializes storage. Removes all parts from all devices leaving them empty
of parts. Deletes ALL storage data from database.
When you activate Initialize Storage, you must close the Manager window
and reopen it again in order to update the storage database.
Note
All devices that do not contain a part or a template at the beginning or at the end of a
complete production round are considered temporary storage devices. (e.g. robot, buffer,
Note machine, conveyor pallets, etc.).

Storage Data Table
The storage devices that appear in the Storage Type column are defined in the Virtual CIM
Setup. For further information, see Edit Menu: New Object in Chapter 7.
ASRS Definition
Click EDIT in the leftmost column of the ASRS row to display the ASRS Storage Definition
form:
Figure 7-10: ASRS Definition Form

Use the following edit options to configure the ASRS:
Option Description
Edit Cell Edits the selected cell. You can fill the cell with a defined part on a
template or fill the cell with an empty template. You also can edit a cell by
double-clicking on any cell to open the Cell Edit form.
Delete Part Deletes the part placed in the template leaving it empty.
Clear Cell Clears the contents of the current cell (i.e. erases both template and part
from this cell).
Template Opens the Templates form where you can define a new template type or
Definition delete an existing one.
The standard Windows options (copy, paste, undo, redo, etc.) are also available.
How to Modify the Contents of an ASRS Storage Cell
Whenever you add or remove a part or a template from a storage cell, use the Storage
Definition form to register the change. The following three procedures explain how to:
Add a part to storage cell.
Add a blank template to a cell.
Clear the contents of a cell
1. Move the cursor to the desired cell and double-click it.

2. Select the part to add from the Part name list box.

Procedure
3. Click to save this change.
Inserting a Part in a
Storage Cell

1. Move the cursor to the desired cell and double-click it.
2. Select the Template number from the Template list box. If the template is
not defined, proceed to define it.
Procedure
Inserting a Blank
Template in a Storage 3. Click to save the change.
Cell
1. Move the cursor to the desired cell.

2. Click the Clear Cell button.
Procedure
Clearing a Storage
Cell
3. Click the Save button to save the change.
How to Define a Template

Templates are special trays that can be customized with an array of pins to hold different
parts. Each part has a unique template type that can hold it. A specific type of template can
hold various types of parts that fit into its pin arrangement.
Each template has a specific six-digit ID number (standard series starting with 010001 to
010040 and ending with 090001 to 090040) that identifies it. This number appears on an
optional sticker that is affixed to the side of the template that faces the barcode or RFID
Reader.
The first (leftmost) two of the six digits represent the template type number. All six digits are
used as an ID number for the specific template.
RFID tags must be assigned a template ID in the RFID device driver. For more information,
refer to the subsection How to Assign a Template ID to an RFID Tag below.
1. Enter the Template Definition in the ASRS form by clicking the

Template Definition button.
Procedure
Adding a Template Code 2. Click the Add New Template button.
3. Type the templates two-digit number.
4. Click the Save button to save the change.
How to Assign a Template ID to an RFID Tag

RFID tags each have a unique tag serial number. In order to use RFID tags in a CIM system,
they must be assigned a template ID.
To assign a template ID to an RFID tag:
1. Launch the RFID device driver as follows:
a) Locate and launch the relevant workstation launcher as described in OpenCIM
Loader: DDLoader.EXE, on page 12-2. The CIM DDLoader is displayed.

Figure 7-11: CIM DDLoader
b) Check the Load column of the RFIDDRIVER driver, and click the Load Selected
Drivers icon. The RFID Device Driver window is displayed.
Figure 7-12: RFID Device Driver

c) From the Control Mode drop down list, select Standalone to switch to Standalone
Mode.
d) Select Settings | Template Lookup Table. The Template Lookup Table is displayed.

Figure 7-13: Template Lookup Table
e) Click Add Row. The Add Template Information window is displayed.
Figure 7-14: Add Template Information Window

f) Pass an RFID tag in front of the RFID reader. The tags unique serial number is
displayed in the RFID tag field.
Figure 7-15: RFID Tag in Add Template Information Window

g) Insert a template ID in the Template ID field, and optionally, a description in the
Comment field.

The RFID tag comment only appears in the RFID Device Driver Lookup Table, and is
intended for identification of the RFID tag (for example, Template 6).
Note
h) Click Save. An entry for the RFID tag is added to the lookup table.
Figure 7-16: Template Lookup Table with Entry

i) To change the Template ID or Comment for any RFID tag, select the tag in the
Template Lookup Table and click Change Row.
j) Click Save Table to save the new entry and close the Template Lookup Table.
k) Pass the RFID tag in front of the RFID reader and verify that the Template ID is
included in the RFID tag entry in the RFID device log.
Figure 7-17: RFID Device Log Entry in RFID Device Driver

l) From the Control Mode drop down list, select Real to switch to Real Mode which is
the normal operational mode.

Feeder Definition
Click EDIT in the leftmost column of the FDR row to display the Feeder Definition form:
Figure 7-18: Feeder Definition Form

During OpenCIM production operations, the message Part not currently
available may be displayed. This indicates that the part feeder, or the ASRS, has run out
of the required part.
Option Description
Part Name The names of all the parts that have been associated with the specified type of
feeder, as defined in the Part Definition form.
Type The number that identifies a certain type of feeder, as defined in the Virtual
CIM Setup.
Capacity The number of units of this type of part / material which can be placed into the
feeder, as defined in the Virtual CIM Setup.
Quantity The number of units currently loaded in the feeder. You must manually update
the value of this field whenever you add parts to or remove parts from the
feeder. The CIM Manager automatically updates this field during production.
Exits and saves any changes.
Exits without saving any changes.

Rack Definition
Click EDIT in the leftmost column of the RACK row to display the Rack Definition form:
Figure 7-19: Rack Definition Form

Option Description
Part Name This list contains the names of all the parts that are associated with the
specified type of feeder, as defined in the Part Definition form.
Type The number that identifies a certain type of rack, as defined in the Virtual CIM
Setup.
Capacity The number of units of this type of part / material which can be placed in the
rack, as defined in the Virtual CIM Setup.
Quantity The number of units currently loaded in the rack. You must manually update
the value of this field whenever you add parts to or remove parts from the
rack. The CIM Manager automatically updates this field during production.
Exits and saves any changes.
Exits without saving any changes.
When editing the storage parameters you must click the create default storage icon
Note for the parts to be added.

MRP
About MRP
Material Requirements Planning (MRP) enables manufacturers to calculate the material
requirements from a list of items they intend to sell. MRP provides a tool for floor control,
master production scheduling and capacity planning. Manufacturing Resource Planning
(MRP II) coordinates and integrates manufacturing resources together with engineering,
marketing and financial resources.
About OpenCIM MRP

The OpenCIM MRP program is used to create and define three types of orders:
Customer Orders: products ordered
Manufacturing Orders: items to be produced
Purchase Orders: items to be purchased from suppliers
In general, OpenCIM MRP allows you to create a list of customers and define the products
ordered by each customer. Once Customer Orders are created, the MRP program
automatically creates a Manufacturing Order and a Purchase Order. You can view and
modify or simply accept the Manufacturing Order, or define a completely new one. When
the Manufacturing Order is submitted, the MRP creates an A-Plan file, or production work
order. (For further details, see A-Plan Report later in this chapter.) In addition, the MRP
creates a Purchase Order for items that must be supplied to the CIM. The OpenCIM Report
Generator can be used to display and print the Purchase Order.
The following figure is a flow chart of the MRP program.
Figure 7-20: MRP Flow Chart

Customer Order Form
When you first activate the MRP, the Customer Order form appears. You can switch to the
other order forms (Manufacturing and Purchase) by clicking the
appropriate tab.
A customer order is a list of the parts (products) ordered by a customer. The Customer Order
form shown below lets you create, view and modify a list of customers and their orders.
Parts must be defined in the Part Definition form before they can be ordered by customers.
Figure 7-21: Customer Order Screen
Toolbar
The following buttons apply only to the Customer Order table. Any changes you make using
these buttons will not be stored in the database until you click Save.
Option Description
Adds a blank row to the Order table.
Saves the selected Customer Order to the database.
Automatically resizes the columns to accommodate long values (when the

window is maximized).
Adds a new customer to the customer list.
Edits the information of the selected customer.
Creates the selected customer order and saves it to the database.
Note: You can only order parts that have been defined as type Product
or Supplied. Phantom parts cannot be ordered.

Order List
Option Description
Required The number of units required by the customer.
Quantity
Priority The priority of this order (19). A priority of 1 is most urgent, 9 is least
urgent. The CIM manager program uses this priority value to determine
the sequence in which to produce orders. Different parts may have the
same priority.
Due Date The shipping deadline for the part. MRP will generate a Manufacturing
Order and Purchase Order that will ensure completion of the part by the
end of the day preceding the deadline.
Note In a commercial CIM environment, this deadline is normally

expressed as a specific date and time. In an educational CIM
environment, the Due Date is relative to the time an order is
submitted. A relative time allows the same order to be
resubmitted day after day without the need to edit the date
field.
How to Define a Customer

When you define a Customer, you are defining the name of the customer for whom a
finished product or products will be made by the CIM cell.
1. In the Customer Order form, click New Customer. The Customer
Data box opens.

Procedure 2. In the Customer Data box, fill in the name of the customer, and other
Defining a New customer information (e.g., address or phone number). Click Save.
Customer The box closes and this customers name is added to the Customer
List.
3. If you want to make any changes to specific customer information,
select the customer from the list, click Edit Customer and make the
desired changes. Note that the customer name cannot be changed in
this option.

How to Define a Customer Order
When you define a customer order, you are defining the type and quantity of finished
products for a specific customer.
1. Add a new customer order to the list by clicking New Order.
2. Right-click in the Customer column to open the customer list. Select
the desired customer.
Procedure
Defining a Customer
3. Right-click in the Part name column to open the part list. Select the
Order desired part, for example: COVERED_BOX.
4. In the Required Quantity field, enter the number of units ordered by
the customer, in this case 3.
5. In the Due Date field enter a value, in this case 2 (i.e., the part is to be
completed in two days). This causes the MRP to instruct the CIM to
begin production immediately.
6. Click Save to save the order for this customer.
7. To order more parts for the same customer in the same order, insert a
new line by right-clicking on the last cell in the order and choosing
Insert After. Repeat steps 2-6.
8. When you have finished filling in the order for a specific customer,
create the order by clicking on MRP.
Manufacturing Order Form

A manufacturing order specifies the type and quantity of parts to be produced by the CIM
cell on a specific day.
The Manufacturing Order form shown can be generated by the MRP program according to
the customer orders currently in the system. You can view and modify or simply accept the
Manufacturing Order, or define a completely new one.
You can define an order at any time, but you must finish defining all machine processes and
subparts used in the order before you submit the order for production.
Each row in the Manufacturing Order table represents a total quantity of a particular part
which needs to be manufactured on the specified date, so that all customer orders are filled.
Figure 7-22: Manufacturing Order Screen
Tool Bar
You can switch to the other order forms by clicking the appropriate tab.
The following buttons apply only to the Manufacturing Order table. Any changes you make
using these buttons will not be stored on disk until you click Save.

Option Description
Adds a blank row to the Order table.
Saves the selected Customer Order to the database.
Auto-resizes the part list columns.
Prints the Manufacturing report.
Prints the A-Plan report for the last manufacturing order

created. (For further details, see A-Plan Report section in
this chapter).
Creates the selected manufacturing order and its A-Plan,
and saves them to the database.
The fields described below compose the Manufacturing Order table:
Option Description
Part Name The name of the products to be manufactured. This field corresponds to
the Part field on the Part Definition form. Right-click in the Part Name
column to open the product list.
Note You can only order parts that have been defined as type
Product. Products that have been defined as type Phantom
or Supplied cannot be ordered.
Total Quantity The total number of units ordered which must be manufactured on the
specified day.
Initial Quantity The number of parts to be extracted from the ASRS when production
begins. The initial quantity is a number that can range from 1 (one) up to
the value of the total quantity. Usually the value is 1 or 2. This field
allows you to optimize the manufacturing process. (Refer to Optimizing
the Scheduling in OpenCIM in Chapter 8, CIM Setup, for more details).
Priority The priority of this order (1-9). A priority of 1 is most urgent, 9 is least
urgent. The CIM Manager uses this priority value to determine the
sequence in which to produce orders.
Due Date The shipping deadline for the part, as generated by the MRP.
Note In a commercial CIM environment, this deadline is

normally expressed as a specific date and time. In an educational CIM
environment, the Due Date is relative to the time an order is submitted.
A relative time allows the same order to be resubmitted day after day
without the need to edit the date field.
How to Create or Modify a Manufacturing Order

A Manufacturing Order is created automatically by clicking the MRP button in the Customer
Order form.
The following procedure explains how to edit or create a Manufacturing Order.

1. Select the order date (number) from the Order List.

2. Click the desired row in the Part Name column and open the product
Procedure list. Select the product required by the customer.
Editing and Submitting 3. In the Total Quantity field, enter the number of items that need to be
a Manufacturing Order produced, in this case 5.
4. In the Initial Quantity field, enter the number of parts to be extracted
from the ASRS when production begins, normally 1 or 2.
5. In the Priority field, enter 1 (indicating the highest priority).
In the Due Date field enter a value which is one greater than the value in
the Order List, in this case 2, indicating that the product will be
manufactured today and ready for shipment tomorrow.
Note To order other products at this time, add a new line by right-
clicking the last cell in the order, choosing Insert After, and
repeating steps 2-6.
6. Click Save to save the entries without changing the last submitted
production plan (A-Plan).
7. Click the MO icon to submit this order and create a new production
plan.
You can now operate the CIM Manager and start production.
How to Submit an Order

Before you click MO and submit the manufacturing order, make sure that the following CIM
definitions are up to date:
Machines and Processes
Parts
Storage
After setting up these CIM elements, you can initiate production. You will receive an error
message if you try to submit an order when any one of the following conditions exists:
An undefined part is referenced on the Manufacturing Order form.
An undefined subpart is referenced in a Part Process table.
An undefined machine process is referenced in a Part Process table.

Purchase Order Form
A purchase order is a list of the parts that need to be supplied to the CIM cell so that it can
complete the Customer Order.
The Purchase Order form shown below can be generated by the MRP program according to
the customer orders currently in the system. You can view and modify or simply accept the
Purchase Order, or define a completely new one.
The Purchase Order form lets you create, view and modify a list of suppliers.
Parts must be defined in the Part Definition form before they can be ordered from suppliers.
Each row in the Purchase Order table represents a total quantity of a particular part which
needs to be purchased by a specified date, so that all customer orders are filled.
Figure 7-23: Purchase Order Screen
Toolbar
You can switch to the other order forms by clicking the appropriate tab above the table.
The following buttons apply only to the Purchase Order table. Any changes you make using
these buttons will not be stored on disk until you click Save.
Option Description
Adds a blank row to the Purchase Order table.
Saves the selected purchase order in database.
Auto-resizes the part list columns.
Allows you to add a new supplier to the Supplier list.
Allows you to edit the information of the selected supplier.
Creates the selected purchase order and saves it in the database.

The following fields compose the Purchase Order table.
Option Description
Part Name The name of the part you want supplied. This field corresponds to the Part
field on the Part Definition screen.
Note: You can only order parts that have been defined as type
Supplied.
Quantity The number of units you want to receive from the supplier.
Cost The cost per unit, as defined in the Part Definition form.
Due Date The date on which the part must be received from the supplier.
Note In a commercial CIM environment, this deadline is normally

expressed as a specific date and time. In an educational CIM
environment, it is an advantage to have the Due Time relative
to the time an order was submitted. A relative time allows the
same order to be resubmitted day after day without the need
to edit this field each time.
Send Date The deadline for sending the Purchase Order to the supplier. Calculated by
subtracting the time required by the Supplier (as defined in the Part
Definition form) from the Due Date.
How to Define a Supplier

When you define a Supplier, you are defining the name of the supplier who will provide
parts for the CIM cell.
1. In the Purchase Order form, click New Supplier to open the Supplier
Data box.

Procedure 2. In the Supplier Data box, fill in the Name of the Supplier, and other
Defining a New Supplier information (e.g., address or phone number). Click Save. The
Supplier box closes and this suppliers name is added to the Supplier List.
3. If you want to make any changes to specific supplier information,
select the Supplier from the list, click Edit Supplier and make the
desired changes. Note that you cannot change your name when editing
supplier details.

How to Create or Modify a Purchase Order
The following procedure explains how to edit or create a Purchase Order.
1. Add a new purchase order to the list by clicking New Order.
2. Click the desired row in the Supplier column and open the supplier list.
Select the name of the desired Supplier.
Procedure
Defining a Customer 3. Click the desired row in the Part name column and open the part list.
Order Select the desired part, for example: BOX.
4. In the Required Quantity field, enter the number of items ordered by
the Supplier, in this case 3.
5. In the Due Date field enter a value, in this case 2 (i.e., the part is to be
completed in two days). This causes the MRP to instruct the CIM to
begin production immediately.
6. Click Save to save the order for this Supplier.
Note To order other products at this time, add a new line by right-
clicking on the last cell in the order, choosing Insert After, and
repeating steps 2-6.
7. If you want to order more parts in the same order, add a new line by
right clicking on the last cell in the order, choose Insert After and
repeat steps 2-6.
8. After you have finished filling in the order for a specific customer,
create the order by clicking MRP.
9. Click the PO button to activate the Report Generator, which will
display or print the Purchase Order.
How to Send a Purchase Order

When you click PO, the MRP program prompts you to enter the date or dates for which you
to print out Purchase Orders.
Since you do not want to send orders too far in advance (which will commit the purchase),
and since you do not want to send a number of orders day after day, the MRP allows you to
consolidate your orders for a period of time, say a week.
Once the dates are entered, the OpenCIM Report Generator menu appears on the screen.
Refer to Purchase Order Report later in this chapter.

Optimization
The order of operation (timing), performed by CIM is controlled using the CIM optimizing
mechanisms, which run concurrently and make decisions based on real-time situations in the
work cell. You can manipulate the behavior of CIM by changing any one mechanism, or a
combination of any of these optimizing mechanisms. This section describes the CIM
Optimization Definition in CIM as well as the additional optimizing mechanisms, described
in Additional Optimization Methods in OpenCIM, at the end of this section.
When activating OpenCIM, parts are dispatched from storage and placed in the queues to the
various machines for processing. In certain cases some parts need to be processed in a
number of different machines. The CIM Manager sorts these parts by creating a virtual
queue of parts that are waiting to be processed in each machine, and the machine in turn
always processes the first part in the queue. Optimization is performed using different
methods for sorting the machine queue. For a general overview of optimization refer to What
is Optimization?, as described in Chapter 2, System Overview.
Even though each queue is managed separately for each machine, the performance is tested for
the overall system.
Note
CIM Optimization Definition

The CIM Optimization Definition enables users to select machine queue algorithms and
define their weight. Users can then observe the effect of the different algorithm combinations
on the overall system performance.
The results generated from the CIM Optimization Definition are displayed in the CIM
Performance Analysis window as described in Performance Analysis.
The CIM Optimization Definition window is displayed by selecting
Utility Programs | Optimization Definition from the OpenCIM Manager main window,
and appears as follows:
Figure 7-24: CIM Optimization Definition

CIM Optimization Definition Window
Main Menu
Option Description
File Contains the following file options: Save and Refresh (described in the toolbar
options below). The Print, Preview and Print Setup options will be defined
later on.
View Contains the following toggle view options: Toolbar, Status Bar
Help Displays the online help.
Toolbar
Option Description
Save: Saves the Machine Queue form to the database .
Refresh: Refreshes the Machine Queue form to the entries that were defined
before the last save.
Queue Per Machine: Displays the list of machines and their alogirithms,
enabling you to select a different algoritm and weight for parts in the queue for
each machine.
Queue Per System: Displays the system algorithm, enabling you to select the
same alogorthim for parts in the queue for all the machines in the system.
Enable Dependancy: Enables finish-to-finish dependency. Meaning, the
algorithms will plan the manufacturing process, to enable all tasks to finish
together (for the overall system). This is performed, for example, by starting
the manufacturing process with the part containing the longest process time
and ending with the part containing the shortest process time.
Disable Dependancy: Disables finish-to-finish dependancy.
Print Optimization: Displays an optimization report.

Machine Queue Form
Figure 7-25: Machine Queue Form Tab in CIM Optimization Definition Window
The Machine Queue Form contains the following fields:
Column Description
Machine Contains a predefined list of all the machines defined in the CIM Setup.
Algorithm The name of the algorithm defined for the parts that are in the queue to the
Name selected machine. You can select the required algorithm from the
dropdown list, as follows:
FIFO (First in First Out): Parts are processed according
to first in first out. Meaning, the parts that arrive first in
the queue are processed first.
Maximum Priority: Parts are processed according to their
priorities (1 through 10) that were defined in the CIM
MRP window. Meaning, the parts with the highest priority
(such as, 1) will be processed first.
Random: Parts are processed based on a random selection
basis.
Shortest Process Time: Parts are processed according to
their process time period. In this case, the parts with the
shortest process time will be processed first.
Algorithm Enables you to enter the weight of the selected algorithm (the total weight
Weight of all algorithms must be 100).
Note Enables you to enter a text comment for reference purposes.
Status Bar
The status bar, shown above, contains the following information:

Option Description
The current machine for which the queue is defined.
The total algorithm weight.
Defines the current queue characterization, as follows:

Option Description
Queue Per Machine: Displayed when the

button is selected from the toolbar. The queue is
defined specifically for each machine.
Queue Per System: Displayed when the

button is selected from the toolbar. The queue is
defined for the whole system.
Defines whether or not finish-to-finish dependancy is activated, as
follows:
Finish to Finish Dependency: Enables process
dependency, displayed when the button is
selected. Meaning, the algorithms will plan the
manufacturing process, to enable all tasks to finish
together (for the overall system).
No Finish to Finish Dependency: Disables part
dependency, displayed when the button is
selected.
Optimization Right-Click Menu
The status bar, shown above, contains the following information:

Option Description
Insert Row Before Enables you to insert a new alogrithm before the selected algorthim.
Insert Row After Enables you to insert a new alogrithm after the selected algorthim.
Delete Row Enables you to delete an existing algorithm.
Note: A minimum of one algorithm exists per machine. When only one
algorithm exists, the system does not enable you to delete it.

Defining Algorithms
The following procedure explains how to define an algorithm in the Optimization Manager
and then run the CIM cell to view the virtual queues of parts that are waiting to be processed
in each machine.
1. From the CIM Project Manager main window, select a project for
which you want to define algorithms.
For example, CIM-04-MQ.
Procedure
Defining Algorithms 2. From the Project Manager toolbar click the CIM Manager
icon. The CIM Manager main window is displayed.
3. Select Utility Programs | Optimization Definition. The CIM
Optimization Definition window is displayed.
Figure 7-26: Defining Algorithms in the CIM Optimization Definition

Window
4. Ensure the Queue per Machine icon is selected (as shown

above) displaying the queue per machine.
5. In the Machine Queue tab select the required algorithm for each
machine from the Algorithm Name dropdown list.
6. Enter the required weight in the Algorithm Weight field.
7. If required you can add additional algorithms for a specific
machine, as follows:
Right click the algorithm. A right-click menu is
displayed.
Select Insert Row Before or Insert Row After to add
an algorithm, and then select the required algorithm
from the Algorithm Name dropdown list.
In the Algorithm Weight column, enter the weight
for each algorithm (ensuring the total algorithm
weight per machine is 100.)
Note: The curent sum of the algorithms is displayed in the status
bar.

8. Click Save and then select File | Exit to close the
Optimization Manager.
9. From the CIM Manager window, select Utility | Part Definition.
Procedure The part definition window is displayed. For each part select a
Defining Algorithms different color. This will enable you to observe the flow of parts
according to their color in the manufacturing cycle. Close the Part
definiton window. Refer to the Part Definition section in this
chapter for further details
10. Select Utility | MRP. The CIM MRP window is displayed. In the
Customer Order tab, select the parts, define their quantities and
then select . Click the Manufacturing Order tab, select the
order to process and click and then click OK. Refer to the
MRP section in this chapter for further details. Close the CIM
MRP window.
11. From the CIM Manager window click the Start button.
Click OK at the confirmation message and then click and
observe the CIM manufacturing cycle.
12. Select Window | Machine Queue. The Machine Queue View
Figure 7-27: Machine Queue View

You can now view the parts which are placed in the machine queues based on
the algorithms that you selected in the Customization Manager window in step
3.

Additional Optimization Methods in OpenCIM
Further to the Optimization Manager, described in the previous section, additional
optimization mechanisms (and their examples) that exist in OpenCIM are described below:
In each manufacturing order line (in the order definition), for each
type of part you can decide how many parts of this type will be
released from storage at the beginning of the manufacturing process
in order to fill the buffers. This number is referred to as "Initial
Quantity".
The release time of each additional part from the ASRS is not set in
terms of time, but rather in terms of the work (part) progress. For
example, an additional similar part is fed to the system only when the
previous part has reached a certain stage in its production plan. This
stage is marked by adding the command NEXT in the definition of
the part production process. The default used for a production plan is
that the system will begin to feed the next part after the last
manufacturing process defined for each part. The default can be
changed by adding the command NEXT in the Process column in the
Part Definition form.
Example
This example demonstrates how to use the NEXT command to set the release time of the
parts from storage.
We will examine part P1, whose manufacturing process requires the use of three machines,
M1, M2, and M3, and the process time of each machine is 2, 7 and 3 minutes respectively.
The schedule for the part is represented as follows (neglecting the transfer times between
the machines):
Figure 7-28: Schedule for Part

If a new part is released every time a part finishes its process at M1, there will be an
accumulation of parts in front of M2, due to its longer process time. Alternatively, if a new
part is released every time a part finishes its process at M2, no queues will be created at any
place in the system, since the process at M2 is the longest. Also, releasing a new part only
after the end of the last process defined for the part will prevent an accumulation of parts.

The problem in this case is that machine M1 will remain idle until the end of the part process
in M2, and even worse, M2, which creates the bottleneck in this example, will remain idle in
between parts. The solution is to release more than one part the first time, in order to fill the
buffers for each of the machines.
In our example, releasing two parts at the beginning of production, and releasing one
additional part each time a part finishes its process at M2, will give maximal throughput of
the production line (since machine M2, which forms the bottleneck, will always be
busy).This also minimizes the in-process stock and leaves a free time-slot for machines M1
and M3 to work on other parts with a lower priority from the same production process. It can
then be seen that the location of the NEXT command immediately after the longest process
results in maximal utilization of the system. On the other hand, locating the NEXT command
at the end of the production process will result in a system which uses more parts in the
buffer, thus continuing to deliver good throughput even in cases of failure, inaccurate data or
a combination of simultaneous production of different types of parts having different priority
levels.
The timing for parts of different types (it is possible that they share the same machines for
part of their production process) uses the same mechanism for each part, and in addition uses
the machine queue mechanism, in order to decide which part will be processed first in a
certain machine. As a simple example, the machine queue mechanism will choose a part
having a higher priority level.
In the following figure, a further example of the process scheduling is given (the same
example but with a different level of detail). Part P1 is the part described above, and part P2
is processed by machines M1 (3 minutes process time) and M4 (2 minutes process time).
The order included four parts of each type and the initial quantity of both parts is two (2).
Part P1 is defined with a higher priority than part P2. The user did not use the NEXT
command for either part, so the system is using the default of putting the NEXT command
after the last process defined for each part.
Figure 7-29: Process Scheduling

P1.1 is the first part of type P1.
P1.2 is the second part of type P1.
P2.1 is the first part of type P2.
P2.2 is the second part of type P2.

Time Machine Description
0 M1 CIM Manager invoked. 2 parts of type P1 and 2 parts of type P2
were sent from storage. M1 selects 1 of the 4 parts based on
priority level (P1.1) to begin processing.
2 M1 Finished processing P1.1 and selects one of the 3 parts remaining
in the buffer (based on the highest priority level) to begin
processing (P1.2).
M2 P1.1 is sent from M1, for processing.
4 M1 Finished processing P1.2 and selects from the queue, based on
priority level one of the two remaining parts (P2.1) to begin
processing.
M2 P1.2 is sent from M1 to wait in the buffer of M2.
7 M1 Finished processing P2.1. Part P2.2 is selected from the queue to
begin processing.
M4 P2.1 is sent from M1 to begin processing.
9 M2 Finished processing P1.1 and begins to process P1.2.
M4 Finished processing P2.1 (the last process) so, the NEXT
command is performed and P2.3, is waiting on the buffer of M1
10 M1 Finished processing P2.2 and P2.3 is selected from the queue to
begin processing.
12 M3 Finished processing P1.1.
M4 Finished processing P2.2. The NEXT command is activated and
part P1.3 is waiting on the buffer of M1.
begin processing.
14 M1 The NEXT command is performed, so P2.4, is waiting on the
buffer.
begin processing.
M2 P1.3 is sent from M1 to wait in the buffer of M2.
M4 Finished processing P2.3. The NEXT command is activated and
P2.4 is waiting on the buffer of M1.
begin processing.
18 M1 Finished processing P2.4. The machine remains idle because there
are no parts waiting in its queue.

Time Machine Description
19 M1 Receives P1.4 which was released from the ASRS as a result of the
NEXT command and begins processing.
M3 Finished processing P1.2. The NEXT command is performed, so
P1.4, is released from the ASRS and sent to M1 for processing.
You can eliminate the inactive time period (Time 18) by increasing
the initial quantity for part P1.
20 M4 Finished processing P2.4. The NEXT command is not performed
because all 4 parts of type P2 are ready.
21 M1 Finished processing P1.4.
begin processing.
26 M3 Finished processing P1.3. The NEXT command is not performed
because all four parts of type P1 are being, or have been processed.
The system works in parallel on orders with both high and low priority, taking into
consideration that orders with high priority are treated first.
Note

Benefits of the Optimization Approach
The Optimization Approach offers the following benefits:
The system continues to follow the priority you define for each part
even though the system is required to work on many parts, from
different priority levels.
The Optimization Approach handles incomplete or incorrect
predicted process time in a competent manner (i.e. the NEXT
command is actually executed when the machine finishes processing
the part and not according to some pre-calculated time).
The Optimization Approach implemented in the CIM environment
can handle different combinations of parts, in different quantities and
priority levels that need to be produced in an efficient manner.
In the example illustrated above the transmission time was neglected.
However, the OpenCIM system still takes the transmission time into
account through the use of its optimization mechanisms. This can
become a significant point when CIM systems have short process
times and the transmission time cannot be overlooked.
Machines, robots, storage locations and even conveyors have their
own priority queue which you can control in order to increase the
performance of the production schedule (e.g. in the example given
above, we assumed that all four parts were sent to machine 1
simultaneously because we ignored the transmission time. However,
in the real CIM, the optimization mechanisms ensure that machine 1
will work on the part with the highest priority level because the
ASRS will know to first select and send the part with the highest
priority level from the four parts that it was ordered to release by the
CIM Manager).
The Optimization Approach is completely distributed. Each machine can continue to work
independently as long as there are parts in its queue. Computational overload does not occur
on any of the station PCs+, even with very large CIM cells.

Performance Analysis
The Performance Analysis utility in OpenCIM enables users to analyze the impact of
different algorithm combinations on the system performance. You can use this utility to
view, print and analyze the manufacturing cycle data to improve system performance, such
as shorten the production time and as a result improve efficiency and lower the production
costs.
The data in this utility is generated according to the definitions in the CIM Optimization
Definition, as described in Optimization.
When activating the CIM Performance Analysis utility, ensure that the simulation speed has
been set to 1 in the Modes window.
Note
CIM Performance Analysis

The CIM Performance Analysis enables you to view information that was generated from the
last manufacturing cycle in the system and then save it for comparison and backup purposes.
You can then view a summary of data comparing the different previously saved
manufacturing cycles. In addition, you can print the currently displayed performance report
and the corresponding optimization report (as displayed in the CIM Optimization
Definition).
The CIM Performance Analysis window is displayed by selecting
Utility Programs | Performance Analysis from the OpenCIM Manager main window, and
appears as follows:
Figure 7-30: CIM Performance Analysis Window

CIM Performance Analysis Window
Main Menu
Option Description
File Contains the following file options: Save, Refresh, Delete All, Print
Performance, Print Optimization, Exit. Each of these options are described in
the Toolbar section below.
View Contains the Toolbar toggle view option.
Tools Show Single, Show Summary, Reset Run ID. Each of these options are
described in the Toolbar section below.
Help Displays the online help.
Toolbar
Option Description
Save: Saves the current manufacturing cycle run performance report to the
database, using the Optimization settings defined in the CIM Optimization
Definition. The Save Report window is displayed, enabling you to add the
cycles description and save it to the PERFORMANCE_X.DBF file. (The
system also saves the corresponding optimization file.)
Refresh: Refreshes the view to display the results from the last manufacturing
cycle run.
Show Single: Displays the Choose Performance File window, enabling you to
select and view a previously saved PERFORMANCE_X.DBF file.
Information per machine includes, total process time, efficiency, Max Queue
Length, Production cost and more. For further details, refer to the Single
Manufacturing Cycle Performance Table, described in the next section.
Show Summary: Displays a summary of all the previously saved
manufacturing cycles. Information per cycle includes, Total Process Time,
Efficiency, Max Queue Length, Production Cost and more. For further details,
refer to the Summary of Manufacturing Cycle Performance Table, described in
the next section.
Reset Run ID: Resets the run ID number to 0. This option is used for example,
when a new Manufacturing Order is created.
Delete All: Deletes all previously saved reports from the database.
Print Performance: Prints the currently displayed performance report.
Print Optimization: Prints the corresponding optimization report as displayed

in the CIM Optimization Definition.
Manufacturing Cycle Performance Table

The CIM Performance Analysis enables you to view the results of the last manufacturing
cycle and save it for future reference. The results include the process time, the efficiency per
machine and per system the number of failures that were detected and so on.

Figure 7-31: Manufacturing Cycle Performance Table
The Manufacturing Cycle Performance Table contains the following information:
Column Description
Machine Contains the list of machines that were defined in the CIM Setup.
Run ID Contains nutsthe ID number of the manufacturing cycle.
Total Run Time The time period of the manufacturing cycle.
Note The manufactuirng cycles description.
Total Process The total process time performed on a specific machine, as well as the
Time system summary which is the total process time of all the machines in the
cycle .
% Efficiency The efficiency of each machine in the cycle, as well as the system
summary which is the efficiency of all the machines together. Machine
efficiency is defined as the process time divided by the total manufacturing
time of the machine.
Max Queue The maximum number of parts that existed in the machine queue during
Length the manufacturing cycle.
Production Costs The production costs per machine and per system. Production costs per
machine is defined as the process time multiplied by the cost per hour
(defined in Machine and Process Definitions).
# Setups (CNC The number of setups that exist in the CNC machine per manufacturing
Only) cycle. A new setup is created each time the CIM Manager instructs the
CNC machine to load a new program. A new program is required when a
new type of part is required for proccessing in the CNC machine.
% Failures (QC The number of part failu
Only) res that were detected in the QC device.
Summary of Manufacturing Cycle Performance Table

The CIM Performance Analysis enables you to view a summary of the different
manufacturing cycles that were saved in the system. This enables you to compare the results
of the cycles, such as the process time, the efficiency, the amount of failures and so on.

Figure 7-32: Summary of Manufacturing Cycle Performance Table
The Summary of Manufacturing Cycle Performance Table contains all the information fields
that were described in the previous section (total process time, efficiency, max queue length,
production cost and more).
Creating Manufacturing Cycle Performance Reports
The following procedure explains how to create manufacturing cycle performance reports for
backup and retrieval purposes.

which you want to define algorithms.
For example, CIM-04-MQ.
Procedure
Creating Manufacturing 2. From the Project Manager toolbar click the CIM Manager
Cycle Performance icon. The CIM Manager main window is displayed.
Reports
3. Select Utility Programs | Optimization Definition. The CIM
Optimization Definition window is displayed, as shown in the
CIM Optimization Manager.
4. In the Machine Queue tab select the required algorithm for each
machine from the Algorithm Name dropdown list, as described in
Defining Algorithms.
5. After defining the algorithms for the manufactuirng cycle, the next
step is to create a manufacturing order, as follows:
Select Utility Programs | MRP. The CIM MRP
window is displayed. In the Customer Order tab,
select the parts, define their quantities and then select
.
Click the Manufacturing Order tab, select the order
to process and click and then click OK.
Refer to the MRP section in this chapter for further details.
Close the CIM MRP window.
6. After creating the manufactuirng order, the next step is to run the
manufacturing cycle, as follows:
From the CIM Manager window click Start ,

and click OK at the confirmation message.
Click Run and observe the CIM manufacturing

cycle.
When the manufacturing order is complete click Stop
7. The next step is to view the performance data.. Select Utility

Programs | Performance Analysis. The CIM Performance
Analysis is displayed showing the performance data from the last
manufacturing cycle.

8. Click Save. The Save Report window is displayed.

Procedure
Creating Manufacturing
Cycle Performance
Reports
Figure 7-33: Save Report Window

9. Enter a description of the manufacturing cycle and click OK. A
message is displayed informing you of the performance file name,
such as Performance_5.DBF for example.
10. Click OK to save the file to the database for retrieving later.
Note: You can click Show Summary to display the

Summary of Manufacturing Cycle Performance Table, as shown
in the previous section.

Viewing Manufacturing Cycle Performance Reports
The following procedure explains how to view predefined manufacturing cycle performance
reports. You can view a single manufacturing cycle report or a summary of all the
manufacturing cycle reports that exist in the system for comparison purposes.
which you want to define algorithms. For example, CIM-04-MQ.

Procedure
2. From the Project Manager toolbar click the CIM Manager icon.
Viewing the The CIM Manager main window is displayed.
Manufacturing Cycle
Performance Table 3. Select Utility Programs | Performance Analysis. The CIM
Performance Analysis window is displayed containing the results from
the last manufacturing cycle run.
Figure 7-34: CIM Performance Analysis
4. Click Show Single . The Choose Performance File window is

displayed.
Figure 7-35: Choose Performance File Window

5. Select the required performance file from the list and click Open. The
Manufacturing Cycle Performance Table of the selected file is
displayed in the CIM Performance Analysis window.

If required, you can print the required performance and optimization
reports as follows:
Click Print Performance to print the currently displayed

performance report.
Click Print Optimization to print the corresponding

optimization report as displayed in the CIM Optimization
Definition.

Reports
The snapshots shown below are all taken from the CIM-08-A-DEMO project provided in
OpenCIM provides a powerful, yet flexible report generator. This utility program allows you
to view and print information from the various OpenCIM databases. You can access ten
types of predefined reports, or you can create your own user-defined reports. The predefined
reports that can be generated are shown in the following figure:
Figure 7-36: OpenCIM Report Generator Dialog Box

The following procedure details the steps involved in generating a report.
1. Select Report Generator from Utility Program in CIM Manager Main Menu;
the OpenCIM Report Generator dialog box appears.

Procedure 2. Select the requested report.
3. Click the Print button. The desired report will appear on the screen. If you
Generating a Report want to print it on a printer, click the printer button on the report screen.

Part Definition Report
The Part Definition Report is generated from information that was entered in the Part
Definition form. It shows the names and description of all parts used by the CIM cell. The
following is an example of a Part Definition Report.
Each of the columns in the Part Report relates to a specific field in the Part Definition form,
as follows:
Part Report Part Definition Form (Field)

# Part # as listed in sequential order.
Part Name Part Name
Type Part Type: supplied, product or phantom.
Part ID Part ID
Template ID Template Type
Part Description Description

Subpart Report
The Subpart Report is generated from information that was entered in the Part Process Table
in the Part Definition form. The Subpart Report is a Bill of Material. It shows all the subparts
which comprise the finished product. The following is an example of a Subpart Report.
Each of the columns in the Subpart Report relates to a specific field in the Part Definition
form.
Subpart Report Part Process Table (Field)

Part Name Part Name.
Sub-Part Name The column Subpart in the Part Process Table.
Manufacturing Process The column Process in the Part Process Table.
Name
Manufacturing The column Parameters in the Part Process Table for each
Parameters corresponding process for a particular subpart.

Manufacturing Order Report
The Manufacturing Order Report displays all production orders for a particular date.
The report is generated from the information that was entered in the Manufacturing Order
form. The following is an example of a Manufacturing Order Report.
Each of the column headings in the Order Report relates to a specific field in the
Manufacturing Order form, as follows:
Manufacturing Order Report Manufacturing Order Form

Part Name The column Part.
There can be more than one part listed.
Total Number of Parts Ordered The column Total Qty.
Each Total Qty listed corresponds to a specific part ordered.
Initial Number to Produce The column Initial Qty.
Each Initial Qty listed corresponds to a specific part ordered.
Priority The column Priority.
The Priority level (from 1 - 9) listed corresponds to a specific
part ordered.
Final Storage Location (if not Refers to the final storage location listed in the column
ASRS) Note (for a specific part).

Machine Report
The Machine Report lists the names of all machines in the OpenCIM cell. This report is
generated from the information that was entered in the Machine Definition form. The
following is an example of a Machine Report.
Each of the columns in the Machine Report relates to a specific field in the Machine
Definition form, as follows:
Machine Report Machine Definition Form (Field)

# The sequential number of the machine as listed.
Machine Name Machine Name
Cost Per Hour Cost Per Hour, in the Machine Process table.
Maximum Number Max Preloaded Programs
of Preloaded Programs
Program 1 List of Preloaded Programs
Program 2
Program 3

Process Report
The Process Report shows the user-defined name (Process Name field) of each machine in
the OpenCIM and the processes performed by the machine. This report is generated from
information that was created from the Machine Process Table in the Machine Definition
form. The following is an example of a Process Report.
Each of the columns in the Process Report relates to a specific field in the Machine
Process Report Machine Process Table (Field)

# The sequential number of the machine as listed.
Machine Name Machine Name.
Process Name The column Process in the Machine Process Table.
Process Type The column Action Type in the Machine Process Table.
Program File Name The column File in the Machine Process Table.

ASRS Report
The ASRS Report shows the contents of the ASRS. It is generated from information that was
entered in the Storage Definition form. The following is an example of an ASRS Report.
Each of the column headings in the ASRS Report relates to a specific field in the Storage
ASRS Report Storage Definition Form (Field)

Name Name of storage location
Index The number displayed in parentheses below the ASRS grid; e.g.,
ASRS (15). This is an internal index used in communication between
the CIM Manager and the ASRS robot controller (and not the Index of
the graphically displayed ASRS cell.)
Part Name The name of the part residing in the current storage cell as defined in
the Part Definition form (refer to cell in grid).
Part ID Part ID, as defined in the Part Definition form.
Status Status of the storage cell (Empty, Empty Template or Part on
Template).
Template Number The six-digit template number.

Analysis Report
The Analysis Report is detailed information on the status of the entire system and is geared
for the more experienced user. The report contains a Log file summary of each action. See
below for an example of an Analysis Report.
The following is a description of each of the columns in the Analysis Report:
Heading Description
Part Name The name of the part as defined in the Part Definition form or in the
Virtual CIM Setup.
Device The name of the robot, machine or conveyor that performs the operation,
as defined in the Machine Definition form.
Action Robot: (pick-and-place)
Assembly: (base and pack)
Conveyor: (deliver) or machine (the name of process as defined in the
Machine Process Table).
Subpart Name Robot: the number of a template or the name of a part.
Machine: the name of a part or material.

Target Where the process should be performed.
Index Indicates the exact location on a device which has more than one location
for a part.
Status The status of the action .
Time The time the action started or the time the action was completed.
Each line in the Analysis Report will have one of the following status reports:
Activate: CIM Manager has determined that a command can be sent
to a machine (e.g., a robot or CNC machine).
In Process: command has been sent to the machine; for example:
GET part from device A (source) and PUT part in device B (target).
Start: Operation has started. Source device may now receive its next
command (i.e., another Activate). Used, for example, to notify
CIM Manager that a pallet can be released from a conveyor station.
Finish: Operation has been completed. Target device may now
receive its next command (i.e., another Activate).
Done (End): The machine is now ready to receive its next command.
Figure 7-37: Analysis Report Flow Chart -

Example for ACL Device Driver

Location Status Report
The Location Status Report is a detailed listing of every location defined in the CIM system.
This report is used by the system administrator or the more experienced user for debugging
the system.
There is more than one type of location.
Locations are defined in the Virtual CIM Setup. Every ASRS compartment, every
station on the conveyor, places on a buffer and places inside the machine.
Every template, a part of an assembly (e.g. one part is on top of another part), a gripper
on a robot, every part in the system.
The Location Status Report enables you to know exactly what and where something is in the
system at a given time. The following is an example of a Location Status Report.
The following is a description of each of the columns in the Location Status Report :
Heading Description
Location The name of the location.
ID The location ID (numeric) as defined in the Virtual CIM Setup.
Index Indicates the exact location on a device which has more than one
location for a part..
Part Name The name of the part in this location as defined in the Part Definition
form.

Status Status of the specified location (Empty, Part on Template, Empty
Template or Part).
Template Number The number of the template at this location.
Type The type of device as defined in the Virtual CIM Setup.
A-Plan Report
The A-Plan Report is a detailed description of the manufacturing process to be performed by
the CIM system. The A-Plan is created when you click MO in a completed Manufacturing
Order form. The A-Plan is a table of sequential instructions which the CIM Manager
executes in order to produce the products being ordered.
This report is intended for the more experienced user. See Experimenting with Production
Strategies Using the A-Plan in Chapter 11, OpenCIM Programming, for detailed information
on how the part will be produced.
The following is an example of an A-Plan Report.

Purchase Order Report
As explained earlier in this chapter, clicking on the PO icon in the MRP program activates
the Report Generator, which will display or print the Purchase Order.
Figure 7-38: Purchase Order Report
User-Defined Report
The User-Defined Report allows you to design and customize a report to the exact
specifications of your CIM system. You can create an unlimited number of User-Defined
Reports.
The Report Generator program employs Seagate (Microsoft) Crystal Report (also available
in Visual Basic) to generate the OpenCIM reports. The Crystal Report program necessary to
create your own user-defined report is not included with the OpenCIM software and must be
purchased separately. Refer to the documentation provided by the Microsoft Visual Basic
Crystal Report for instructions on how to create a report.

8
Virtual CIM Setup
The Virtual CIM Setup is an interactive graphic module that allows you to create a simulated
CIM cell. The CIM cell may contain the actual elements and connections of a real CIM
installation, or it may define a theoretical (meaning, virtual) CIM cell. This chapter includes
the following sections:
CIM Setup Overview, introduces the OpenCIM Setup application.
Accessing CIM Setup, describes how to access the virtual CIM
Setup application.
CIM Setup Main Window, describes the components of the CIM
Setup interface.
Working with the CIM Setup, provides guidelines for setting up
and working in your CIM cell.
Tutorial, describes step by step instructions for designing and
operating a CIM cell.

Virtual CIM Setup
CIM Setup Overview
The first part of this chapter presents the menus and screen elements of the Virtual CIM
Setup module. You are then encouraged to perform the Tutorial, which will enable you to
practice using this module and create a Virtual CIM.
Click the Virtual CIM Setup icon to open the Setup screen. A number of menus are
available, but many menu items will not be available until a setup has been created or
loaded.
Virtual CIM Setup Limitations

The Virtual CIM Setup allows you to construct all sorts of CIM cells, although some
configurations would be difficult or even impossible, to actually operate. To ensure your
success in operating a Virtual CIM cell, create your cell in accordance with the following
guidelines:
Use only one conveyor in the cell.
Use no more than eight stations around the conveyor.

Virtual CIM Setup
Accessing CIM Setup
The CIM Setup application is accessed from the Project Manager main window, enabling the
user to create and modify the Virtual CIM setup of the selected CIM Cell.
To access the CIM Setup application:
From the Project Manager Main window, shown in Chapter 5, Project Manager, click CIM
Setup on the toolbar. The Virtual CIM Setup Main window is displayed, as shown in
Figure 8-1.

Virtual CIM Setup
CIM Setup Main Window
The Virtual CIM Setup Main Window appears, as follows:
Figure 8-1: Virtual CIM Setup Main Window

The Virtual CIM Setup window, shown above, contains the following elements, each of
which is described in the sections that follow:
CIM Setup Menu Bar
CIM Setup Toolbar

Virtual CIM Setup
Virtual CIM Setup Menu Bar
The Virtual CIM Setup menu bar contains five menus, each of which is described in detail in
the sections that follow.
File Menu
The following table contains a brief description of each option in the File menu:
Option Description
Save Saves the current placement of all objects in the CIM cell.
Exit Exits the Virtual CIM Setup module. You will be prompted to save
the current placement of objects.
Create Menu
The following table contains a brief description of each option in the Create menu:
Option Description
Group The system automatically creates shortcuts to loaders for drivers of
all the workstations in the selected project. This group contains
shortcuts to loaders that are required in order to operate the CIM
cell defined by the Virtual CIM Setup.
The group can be accessed from the following directory path:
Windows XP: [default system drive (for example C:)]\\Documents
and Settings\All Users\
Documents\Intelitek\OpenCIM\Projects\<name of
project>\OpenCIM<name of project>
Windows Vista/7: [default system drive (for example
C:)]\Users\Public\Documents\Intelitek\OpenCIM\Projects\<name
of project>\OpenCIM<name of project>
Setup File Prompts you to confirm the overwrite of the SETUP.CIM file. For
full details, refer to Chapter 12, Inside OpenCIM
Loader Section Creates a file WSn.INI for each station (e.g. WS2.INI).
ACL DMC File Prompts you to confirm the overwrite of the DEVICE.DMC file.
For full details, refer to Chapter 9, OpenCIM Device Drivers, and
Chapter 12, Inside OpenCIM.

Virtual CIM Setup
Edit Menu
The following table contains a brief description of each option in the Edit menu:
Option Description
New Object Displays the New Objects dialog box, enabling you to add new
elements to your new CIM cell, as described, for example in Adding
a Conveyor.
The New Objects dialog box contains all the elements which can be
included in the Virtual CIM Setup, as follows:
Double click on the [+] button of a category in
order to expand its list of elements and select an
object.
Move the cursor into the graphic scene. The cursor
changes to a cube. Point and click on the location
where you want to place the object. You may need
to wait a moment for it to appear; do not double-
click.
Delete Object Activates the delete mode in order to delete an object from the cell.
Using the cursor, point and click on the object you want to delete.
Click Yes to confirm the deletion. If you click No, the delete mode
remains in effect, enabling you to select and delete another object.
Drag Object Enables you to pick an object and drag it through the cell
Setup IDs Displays the Edit IDs dialog box, containing a list of all the objects
and ID numbers in the cell, enabling you to change the ID number
of a device. Double-click on the highlighted line, and enter a new
number at the prompt.
Figure 8-2: Edit Setup IDs Menu

Once you have changed an ID, be sure to select
Create | Setup File and Create | ACL DMC File in order for the
change to take effect.

Virtual CIM Setup
Option Description
Floor Size Opens the Set Floor Size dialog box that enables you to set the X
and Y dimensionsof the cell. Click OK to confirm the new size or
Cancel to close the dialog box.
Set Textures Opens a sub-menu listing cell textures:floor, land and background
enabling you to select the required *.bmp file for the specified
texture.
Building Displays the walls of the building in the CIM Cell.
View Menu
The following table contains a brief description of each option in the View menu:
Option Description
Show Names Displays the names of all devices in the scene.
Show IDs Displays the device ID numbers.
Show Positions Displays the position coordinates of all devices.
Redirect Camera Allows you to select a different focal point in the scene.
Drag 3D Frame Allows you to drag the cell.
Camera Top Displays the overhead view of the scene.
Scene Origin Displays the scene origin, e.g. coordinate 0,0 of the room.When
selected, a red cross is displayed in the center of the shop floor.
Toolbar Displays or hides the toolbar.
Status Bar Displays or hides the status bar.
The options in this menu are similar to those in the View menu of the Graphic Display and
Tracking module. For full details, refer to Chapter 6, Operating CIM Manager
Note

Virtual CIM Setup
Virtual CIM Setup Toolbar
The toolbar icons provide quick access to the most commonly used functions in the Virtual
CIM Setup window and appear as follows:
The following table contains a brief description of each option on the CIM Manager toolbar:
Option Description
Save:Saves the current placement of all objects in the CIM cell.
Groups: The system automatically creates a group of icons in your windows

Start menu of the selected project.
Setup: Prompts you to confirm the overwrite of the SETUP.CIM file. For full
details, refer to Chapter 12, Inside OpenCIM .
Loader: Creates a file WSn.INI for each station (e.g. WS2.INI).
New Object: Displays the New Objects dialog box, enabling you to add new
elements to your new CIM cell as descibed, for example, in Adding a
Conveyor.
Delete Object: Deletes currently selected object.
Drag Object: Allows dragging of object from one location to another.
Show Name: Shows name of the object.
Show ID: Shows ID of the object.
Show Position: Shows coordinates (from bottom left corner).
Redirect: Defines the position that will be in the center of the image.
Camera Top: Places the camera on top of the cell at the center of the image,
Drag 3D Frame: Enables you to pan the CIM cell left, right, up and down.

Virtual CIM Setup
Configuration Parameters Popup Menus
The Virtual CIM cell contains configuration parameters popup menus that are displayed
when you double-click on an object in the Virtual CIM. The following figure shows some of
the variations of the Configuration Parameters menu.
Figure 8-3: Parameter Configuration Popup Menus

Once defined and saved, these parameters are written to OpenCIM INI files, as described in
Chapter 12, Inside OpenCIM.
The following table contains a list as well as the description of all parameters that can be
defined. The parameters for many objects do not normally require manipulation. The
Tutorial at the end of this chapter demonstrates the recommended sequence and actions for
setting object parameters.
Option Description
Capacity Defines the number of items that the device can hold.
You must define a value for feeders, racks and trash bin. For most other
objects you can accept the system-defined value.
When selecting new objects, select Buffer 2 for a buffer whose capacity is
two items, and select Buffer 1 for a buffer that can contain only one item.
The capacity parameter is thus already defined as 2 and 1, respectively.
Figure 8-4: Defining Capacity

Virtual CIM Setup
Option Description
CommPort For ACL device drivers, the settings must be as follows:
BaudRate = 9600
Parity = None
DataBits = 8
StopBits = 1
XonXoff = No
These are the standard RS232 settings for communicating with ACL
controllers (both Controller-A and Controller-B). These settings should not
be changed since they match the fixed settings in the controller.
For the PLC device driver, the settings will be one of the following:
OMROM PLC Allen-Bradley PLC LG PLC
BaudRate = 9600 BaudRate = 9600 BaudRate = 9600
Parity = Even Parity = None Parity = None
DataBits = 7 DataBits = 8 DataBits = 8
StopBits = 2 StopBits = 1 StopBits = 1
XonXoff = No XonXoff = No XonXoff = No
These are the RS232 parameters used by the PLC device driver when it
communicates with the PLC. You must set these parameters to match the
RS232 settings on the PLC.
Connectivity Connects all objects and their associated device drivers.
Also connects robots to all objects which are physically within their reach
and to all objects which can be connected by means of an RS232 cable.
When you click on Connectivity, the Connections menu opens.
Figure 8-5: Defining Connections

Virtual CIM Setup
Option Description
One or more connections can be added or deleted at a time.
To make a connection, highlight the device driver name(s) for the
selected object, click Add, and then OK.
To remove a connection, highlight the device driver name(s) for
the selected object, click Remove, and then OK.
Active Connections: A list of all connections that have already been
established between this and other objects.
Possible Connections: A list of all objects to which this object can be
connected. For robots, this list will also display all devices that are in
physical reach of the robot (i.e., that are in the Work Volume of the robot),
and all objects that can be connected by means of an RS232 cable.
Possible Connections for Robots will also display all the device drivers for
this robot within the CIM cell, since robot controllers can communicate
with any PC in the CIM cell. Normally, you should select only one robot
device driver per robot. Do not select device drivers that are not intended
for this robot.
If you want to connect an object (not a device driver) to the robot, and the
object is not within reach of a robot, reposition it on the screen until you
see the objects name appear in the list of possible connections.
Conversely, if you move an object too far away from a robot, the
connection will be severed. A warning will prompt you to reposition the
objects and reestablish the connections, if desired.
Figure 8-6: Robot Connections
Tip: To see which device driver belongs to an object, click on the object.
From the objects Parameter Configuration menu, select Connectivity|OK.
A line connecting the object and its associated device driver appears on
the screen . (Alternatively, click on a device driver to find its associated
device.)
Green lines show the connections between device drivers and their
associated objects. Red lines show the physical connections between
robots and other objects; i.e., devices that are within the robots reach.

Virtual CIM Setup
Option Description
Green lines indicate which software is running on a PC. Click on a PC. To
see the green lines, select Show Connection from the Parameter
Configuration menu.
Figure 8-7: Workstation Connections

External ID Unique numerical Device ID that identifies each device in the system. The
software defines IDs automatically in sequence as the devices are created
in the Virtual CIM cell. You can, however, modify this ID in order to
structure the numbering of the devices, for example, in relation to the
station they are located in (see example in the tutorial).
Location Identifies the location of a feeder when it is placed and used within an
ASRS unit. (In an actual CIM cell, a feeder can only be placed on an
ASRS carousel, not in the ASRS2, ASRS-36u, or ASRS-36x2.)
Properties Defines the Workstation (WSn) at which the objects device driver is
connected and running.
Also defines the INI file associated with the objects device driver. This
INI file contains the definitions and parameters for the object, and is
invoked by the device drivers Loader command line.
Figure 8-8: Defining Workstation for Device Driver

Once Properties have been defined for a device driver, other options in the
Parameter Configuration menu become available.

Virtual CIM Setup
Option Description
QC Report The Quality Control device driver allows you to write the results of a QC
test to an ASCII text file that can be input to a spreadsheet program.
Delete on Start. This switch controls whether a new quality control
report file will be created each time this device driver is activated.
If checked (Yes), the previous file is deleted; if not checked (No),
results are appended to the existing report file.
Figure 8-9: Defining Quality Control Report

Rotate Rotates a displayed object to any degree. Useful, for example, to properly
attach buffers to the conveyor, or to logically orient a PC in the Virtual
CIM display.
Sub Type System-defined parameter. Normally, you do not need to manipulate this
parameter.
Variables The default values for the variables used by the CNC script.
Write Load Creates the WSn.INI file for the particular workstation.

Virtual CIM Setup
Working with the CIM Setup
This section describes how to set up your CIM Cell and provides guidelines for creating
conveyors (user defined, rectangular and L-shaped), as well as adding stations, tables and
robots and so on. It includes the following:
Creating a User Defined Conveyor
Creating a Rectangular
Creating an L-Shaped Conveyor
Adding Tables
Adding Robots
Manipulating the Graphic Display
Creating a User Defined Conveyor

Since the Virtual CIM conveyor is the most difficult of the elements to place in the scene,
this section contains detailed, procedural instructions for creating a conveyor.
If you are replicating an actual CIM cell, you will need to know the exact dimensions of the
conveyor.
To add a user defined conveyor:
2. Select Edit | New Object. The New Objects dialog box is displayed.
Figure 8-10: New Objects Dialog Box

Virtual CIM Setup
3. From the General tree select Conveyor. The Conveyor dialog box is displayed.
Figure 8-11: Conveyor Dialog Box

4. From the Type area, select User Defined.
5. Select the required option, as follows:
6. Select Zoom In to place a typical 3m X 4m OpenCIM conveyor (with straight segments
of 1.40m). Each grid represents about20 cm. When Zoom In is not selected, the grid
resolution is increased, which enables you to place a larger conveyor (8 m x 10 m) into
the CIM cell
7. Select Table Top to place the conveyor on a table.
8. Click OK. A grid will appear on the screen. The set of numbers displayed on the left are
the screen pixel coordinates of the cursor, while the numbers on the right are metric
coordinates (in meters).
When creating a conveyor, use the mouse buttons as follows:

Click with the right mouse button and drag to select menu options
Note
Point and left-click to place objects on the grid.
To select the starting point of the conveyor, do the following:
1. Place the cursor on the grid and right-click to open this icon menu:
The key icon is used to mark the starting point of the conveyor.
The spectacles icon opens another icon menu. Do not attempt to
manipulate the displayed values. These settings are for technical
support personnel only.
The grid icon toggles the grid display on and off.

Virtual CIM Setup
2. Drag and select the key icon. A wand-pointer appears on the screen. Use this cursor to
click on a starting point for the conveyor. It should be placed on the right side of the
grid, as shown in Figure 8-12: Adding Conveyor Segments. A red dot appears on the
grid.
Since the conveyor movement is normally counterclockwise, the conveyor segments are
added in the counterclockwise direction.
To create the conveyor, do the following:
1. Again click on the right mouse button. An icon menu will open.
Segment icons: The first six icons represent segments of the conveyor.
Segments are added and connected in consecutive order.
To insert a straight segment, select either the horizontal or vertical bar.
Using the left mouse button, place the pointer on the square whose upper
left hand corner marks the end of the segment you want to add. Carefully
position the cursor in order to align the segments of the conveyor
Reverse: The white curved arrow in the blue circle is used to

reverse the direction of conveyor movement. When this icon is selected,
conveyor movement is clockwise, and the segments will be added
accordingly.
Undo. The undo icon cancels the last segment(s) added to the
conveyor. Undo is available after the first segment has been placed on the
grid.
OK. This button will appear when you have completely connected
all segments of the conveyor.
Spectacles: The spectacles icon opens another popup menu.
Do not attempt to manipulate the displayed values. These settings are for
technical support personnel only.
2. Using the icon menu, select and connect each segment of the conveyor.
Figure 8-12: Adding Conveyor Segments
Avoid using too many UNDOs while drawing the conveyor; a faulty display may result.
When drawing the conveyor, do not extend the straight segments too close to the edge. Allow
Tips
enough room for the corner segments.
3. When you have completed drawing the conveyor, click on the button. A chain of
dots will appear in the conveyor.

Virtual CIM Setup
Creating a Rectangular Conveyor
As an alternative to creating your own user defined conveyor (described in Creating a User
Defined Conveyor), the Virtual CIM Setup also enables you to select a predefined
rectangular conveyor. This includes, defining the conveyor dimensions and zoom options
and so on.
To add a rectangular conveyor:
1. Select Edit | New Object. The New Objects dialog box is displayed as shown in Figure
8-10: New Objects Dialog Box.
2. From the General tree, select Conveyor and then click OK. The Conveyor dialog box is
displayed, as shown in Figure 8-11: Conveyor Dialog Box.
3. Select Rectangular and define the conveyor dimensions in the Size area.
1. Select Zoom In to place a typical 3m X 4m OpenCIM conveyor (with straight
segments of 1.40m). Each grid represents about 20 cm. When Zoom In is not
selected, the grid resolution is increased, which enables you to place a larger
conveyor (8 m x 10 m) into the CIM cell
5. Click OK. A Rectangular conveyor is displayed, as shown in the following example:
Figure 8-13: Rectangular Conveyor

Virtual CIM Setup
Creating an L-Shaped Conveyor
As an alternative to creating your own user defined conveyor,(described in Creating a User
Defined Conveyor), the Virtual CIM Setup also enables you to select a predefined L-Shaped
conveyor. This includes, defining the conveyor dimensions and zoom options and so on.
To add an L-Shaped conveyor:
1. Select Edit | New Object. The New Objects dialog box is displayed as shown in Figure
8-10: New Objects Dialog Box
2. From the General tree, select Conveyor and then click OK. The Conveyor dialog box
is displayed, as shown in Figure 8-11: Conveyor Dialog Box.
3. Select L-Shaped and define the conveyor dimensions in the Size area.
1. Select Zoom In to place a typical 3m X 4m OpenCIM conveyor (with straight
segments of 1.40m). Each grid represents about20 cm. When Zoom In is not
selected, the grid resolution is increased, which enables you to place a larger
conveyor (8 m x 10 m) into the CIM cell
5. Click OK. An L-Shaped conveyor is displayed, as shown in the following example:
Figure 8-14: L-Shaped Conveyor Segments

Virtual CIM Setup
Adding Stations
After defining the conveyor you must place the required stations around the conveyor. This
includes defining the station location and number and so on.
To add stations around the conveyor:
1. Click on the right mouse button. A popup menu is displayed.
2. Select the Station icon. Then point and click on one of the dots in the conveyor.
The Conveyor Stations dialog box is displayed.
Figure 8-15: Conveyor Stations Dialog Box

3. Enter the station number in the field provided and click OK.
Tip The first station should immediately follow the starting point of the conveyor, in accordance with
the counterclockwise or clockwise movement of the conveyor. Additional stations should be
placed consecutively in the same direction until you reach the starting point again. It is
recommended that you plan your conveyor in advance to determine the correct location for each
station.
Figure 8-16: Adding Conveyor Stations
Place stations on straight segments of the conveyor. They cannot be placed on the curves.
Tip
4. Repeat steps 2 through 3 for each conveyor station.
5. Select the File icon to save the conveyor definitions.

Virtual CIM Setup
Once you have saved the conveyor setup, the conveyor will be drawn on the CIM scene
window.
Do not save the conveyor until you have placed ALL stations around the conveyor. Once a
conveyor has been saved, it cannot be altered. To change a conveyor configuration, you
Note
will need to repeat the entire procedure.
Adding Tables
Tables should be placed at every station around the conveyor, either after the conveyor is
created, or after all elements have been placed in the scene.
When you place objects in the Virtual CIM, you do not need to define a height coordinate,
since the system assumes all objects are at their proper heights. All objects will be displayed
at the correct height, even if they are not sitting on tables.
You can select size and color of any table you want to create, but only before you create it.
Once the table is made it cannot be altered. To make any changes in tables properties you
will need to repeat the entire procedure.
It is recommended that you place tables in the Virtual CIM so that objects at the stations will
not appear to float in space.
Notes
To place a table on the Virtual CIM, do the following:

1. Select Edit | New Object The New Objects dialog box is displayed, as shown in Figure
8-10: New Objects Dialog Box.
2. From the General tree select Table and then click OK. The Table dialog box is
displayed.
Figure 8-17: Table Dialog Box

3. Click the Colors button to change the table color.
4. In the Size area, define the dimensions of the table and click OK.
5. Point and click on a spot near the first conveyor station to place the first table.
6. Repeat steps 2 through 5 to place tables at all the stations around the conveyor.

Virtual CIM Setup
7. Click and drag on the cursor to adjust the location of each table in the scene.
The coordinates that appear on the table (and any other object that you manipulate)
mark the center point of the table or object relative to the cross at the center of the shop
floor, which is displayed by selecting Scene Origin from the view menu.
Figure 8-18: Adding Tables

Virtual CIM Setup
Adding Robots
As indicated at the beginning of this chapter, after the conveyor is created, you should add
the ASRS, robots, machines and other devices.
By default the system automatically assigns numbers to the robots (and all other objects) in
the order of creation. You should therefore place your first robot (Storage robot ) at Station
1, the second robot at Station 2, and so on.
To add robots:
1. Select Edit | New Object The New Objects dialog box is displayed.
2. From the Robots tree click the Robot to add (ER 4u, for example) and then click OK.
The Optional LSB box is displayed. .
Figure 8-19: Optional LSB Dialog Box

3. If the robot is to be placed on a slidebase, enter the slidebase size in meters and click
OK. Otherwise, click Cancel.
If the slidebase requires a stand, check LSB Stand in the dialog box and click OK.
4. Point and click on a spot at the first station to place the first robot. Repeat this step for
each station around the conveyor.
5. Double-click on a robot to open its Configuration Parameters popup menu.
The Robot Configuration Parameters menu differs from the Table Configuration Parameters
menu. Each object in the Virtual CIM has a particular Configuration Parameters menu, as
described in the Configuration Parameters Popup Menus section
Manipulating the Graphic Display

The Virtual CIM Setup module uses the same method as the Graphic Display module for
manipulating the view of the CIM cell.
1. To change the angle of the overhead scene, place the cursor on the
vertical scroll bar and drag it up and down.

Procedure 2. To rotate the scene, place the cursor anywhere on the screen and:
Manipulating the Click the right mouse button and drag to the
Graphic Display right to rotate the display counterclockwise.
Click the right mouse button and drag to the
left to rotate the display clockwise.
3. To zoom the scene, place the cursor anywhere on the screen and:
Click the right mouse button and drag up to
zoom in.
Click the right mouse button and drag down
to zoom out.

Virtual CIM Setup
1. Click on View|Redirect Camera.

2. Click any object in the scene. It now becomes the center point for the

Procedure display manipulation. The view changes to an overhead scene (if it is
Changing the Focus of
not already), which you can now manipulate, as described in
the Graphic Display Manipulating the Graphic Display.

Virtual CIM Setup
Tutorial
In this tutorial you will learn to create and run an OpenCIM cell which contains three
stations. It includes the following:
Stage 1: Designing the CIM Cell: Describes how to create a graphic
CIM cell using the Virtual CIM module.
Stage 2: Operating the CIM Cell: Describes how to define and
operate the CIM cell using the CIM Definition and CIM Operation
modules. You will also use the Graphic Display module to view your
CIM cell in operation.
Stage 1: Designing the CIM Cell

The following procedure is the recommended sequence for setting up the Virtual CIM Cell.
1. Plan and document your CIM system before starting.
2. Define the conveyor and the location of the workstations.

Procedure 3. Place tables at the stations.
Setting up the Virtual 4. Place an ASRS device at a workstation (station 1 is recommended).
CIM Cell 5. Place robots at the stations.
6. Place CNC and any other machines at the stations.
7. Place buffers at the workstations.
8. Place PCs at the workstations.
9. Define the device drivers for the workstations.
10. Define all connections and properties for each device driver.
11. Create the Setup, Map and Icon Group for this CIM cell.
This section will guide you through a complete procedure for creating an OpenCIM cell
using the Virtual CIM Setup module.

Virtual CIM Setup
To design the CIM Cell:
1. From the Project Manager main window, click New on the toolbar. The New
Project dialog box is displayed.
Figure 8-20: New Project Dialog Box

2. In the Project name field, enter CIM-1 and click OK. The new project is displayed in
the User Project tab in the Project Manager main window (for further details refer to
Chapter 5, Project Manager).
3. Select the CIM-1 project and click the Virtual CIM Setup icon on the toolbar.
The Virtual CIM Setup main window is displayed, as shown in Chapter 8, OpenCIM
Setup.
4. Select Edit | New Object. In the New Objects window, double-click General to expand
the tree, and then select Conveyor. The Conveyor dialog box is displayed.
Figure 8-21: Conveyor Dialog Box

5. From the Type area, select User Defined and click OK. The Conveyor grid appears.
Click the right mouse button. Drag the mouse and then select the key icon .
6. A wand appears. Bring the wand into the lower right side of the grid and click the left
button. A red dot appears; this is the conveyor starting point.
7. Click the right mouse button. Drag and select the vertical segment. Point and click the
cursor on a spot above the starting point.
8. Select an arc-up-and-left segment. (The conveyor is created in the direction of
movement; normally counter-clockwise.)

Virtual CIM Setup
9. Continue selecting and adding segments to the conveyor until it is complete. Use the
curved arrow to undo any mistakes. (Avoid using too many undos.)
10. When the conveyor is complete, click the right mouse button and then click the
icon.
11. Click the right mouse button and select the Station icon from the popup menu, to
create a station. Point to a location just above the starting point of the conveyor (not on
the curve). Click the left mouse button. Accept the prompt for Station number 1.
12. Add the stations in accordance with the counterclockwise or clockwise movement of the
conveyor.
13. Repeat the previous step for two more stations. Add the stations in consecutive order
around the conveyor.
14. When all three stations are marked around the conveyor, click the right mouse button
and select the File icon from the pop-up menu to save the conveyor and click OK to
save the conveyor setup.
15. The grid closes, and a cube cursor appears on the screen Bring the cursor to the center of
the screen and click. (To display a red cross marking the center of the shop floor, select
Scene Origin from the view menu). The conveyor appears in the Scene Window. Click
on the conveyor and drag with the left mouse button to center the conveyor on the floor.
16. Select File | Save to save your work.
17. Select Edit | New Object | Storage | ASRS36.
18. Click the left mouse button near Station 1. The ASRS36 appears on the screen. (This
object is the robot that has a storage rack with 36 shelves.)
19. Click on the ASRS36. The objects parameter configuration submenu opens. Select
Rotate. Enter 90. The lower small frame should be outside the conveyor. Adjust the
orientation and position of the ASRS36.
20. Add Tables for the workstations.
21. Add objects to Stations 2 and 3, as follows:
At Station 2, select Robots | ER 9, and enter 1.0 (meters) at the prompt for LSB
(robot will be mounted on a linear slidebase).
At Station 3, select Robots | ER 14, and then click Cancel at the prompt for LSB.
During the selection and placement of new objects, wait for the cursor to settle in place.
Avoid double-clicking.
Your screen should now look like this:
Figure 8-22: Conveyor Stations and Objects

Virtual CIM Setup
22. Using the same procedure you used for placing robots at stations, add the following
objects to the CIM cell:
At Station 2: EXPERTMILL VMC-600.
At Station 3: Jig-XY, Screwdriver, and Vision Camera.
As you work, rotate and reposition the objects on the shop floor.
Use Redirect View and Zoom to help you with the placement of objects.
Save your work regularly when creating the CIM cell.
23. Add station buffers (Buffer 2) around the conveyor, in the following order:
Station 1
Station 2
Station 3
24. Select Edit | Delete Object and click on the buffer you placed at Station 1. The buffer
will be erased. (The ASRS36 does not require a buffer, but a temporary buffer was
created at Station 1 causing the buffers at the other stations to be named BFFR2 and
BFFR3, respectively.)
25. Rotate the buffer at Station 3 90. Adjust the location of other buffers, so that they are
attached to the conveyor and within reach of the robot at the station.
26. At station 3 add a Rack, Feeder and Trash. The following figure will guide you in
properly placing all the objects at this station.
Figure 8-23: Placing Station Objects

Virtual CIM Setup
27. Save your work at this point.
28. Add workstations (PCs) for each station. Start with the Manager PC and then continue
with the Station PCs for Station 1, 2 and 3.
29. Scale Tables for the workstations and arrange them as shown below:
Figure 8-24: Placing Station Tables

30. Add device drivers near the PC at each station:
For each robot at the station (including the ASRS36): add Scorbase device driver.
For a CNC machine (lathe/mill): add a CNC device driver.
For the Vision Camera: add a ViewFlex device driver.
For the Conveyor: add a PLC device driver. Place it at Station 1.
The Jig-XY and Screwdriver are controlled by the Scorbase controller (and its device
driver), and do not require device drivers of their own.
31. For each device driver, you will need to set its properties and connections. Click on each
object in order to open the corresponding parameter configuration menu, and do the
following:
Click on Properties. Select the number of the workstation at which the device
driver is running (e.g., WS1 for ASRS36 and PLC).
Click on the device driver and enter the commport settings
Click on Connectivity:
Connect the PLC device driver (PLCVD1) to the conveyor (CNV1).
Connect each Scorbase device driver (A SCBSVDn) to its corresponding
robot (ROBOTn).
Connect each CNC device driver (CNCVDn) to its corresponding CNC
machine (EXPERTMILLn or PLT3000).

Virtual CIM Setup
32. For each robot, select Connectivity and make the connections to all objects which are
physically within its reach. Connect each robot to the conveyor station (CNV1#n), the
station buffer (BFFRn) and all machines and devices at its station. Make sure the
appropriate device driver is connected to the robot. If you are unable to make a
connection, move the robot and device closer to each other, and try again.
33. Connect the Screwdriver and the Vision Camera to the Jig-XY only.
34. For the Feeder:
SubType : Set to 101.
Capacity: Set to 10.
For the Rack:
SubType: Set to 201.
Capacity: Set to 9.
From the Create menu, perform the following:
Select Loader Section.
Select Setup File and then click OK at the prompt to overwrite the SETUP.CIM
file.
Select Group. This will create a directory which contains all the shortcuts needed
to prepare and operate the CIM-1 project. You can display this folder by browsing
to [projects directory]\CIM1\OPENCIM CIM1 in Windows explorer.
35. Save and exit the Virtual CIM Setup module.

Virtual CIM Setup
Stage 2: Operating the CIM Cell
This part of the tutorial will give you practical experience in using the CIM operation
modules. The following steps all relate to the CIM-1 program group which you have created
in the Virtual CIM Setup.
To operate the CIM Cell:
1. From the Project Manager main window, select the User Projects tab and then select the
CIM-1 project.
2. From the Project Manager toolbar, select CIM Manager . The CIM Manager main
window is displayed for the CIM-1 project.
3. Select Utility Programs | Machine Definition. The CIM Machine Definition window is
displayed.
4. In the CIM Machine Definition window perform the following:
From the Machine Name list, select EXPERTMILL1, and enter the following
information:
Process Name: PROG_BOX1
File Name: 1.GC
Program: leave blank
Duration: 00:00:25
5. Click Save.
6. Close the CIM Machine Definition window.
7. Select Utility Programs | Part Definition. The CIM Part Definition window is
displayed.
8. In the CIM Part Definition window perform the following:
Select the Supplied Parts tab.
Select File | New Part to define a new part, and enter the following information:
Part Name: CUBE
Part ID: 77
Template Type: 01
9. Click Save, and check the Errors box. The message Save done indicates there are no
errors.
10. Select the Product Parts tab.
11. Select File | New Part to define a new product part, and enter the following
information:
Part Name: BOX.
Part ID: 75
Sub part: CUBE
Process: PROG_BOX1
Template Type: 01
12. Click Save, and check the Errors box. The message Save done indicates there are no
errors.
13. Close the CIM Part Definition window.
14. Select Utility Programs | Storage Manager. The CIM Storage Manager window is
displayed.

Virtual CIM Setup
15. In the CIM Storage Manager window perform the following:
1. Click the Edit button of the ASRS storage type. The CIM Storage Definition
2. Double click any cell in the grid. The Cell Edit dialog box is displayed.
3. Select CUBE from the Part drop-down list and click Save to close the Cell Edit
dialog box.
4. Repeat these steps three more times for other cells.
5. Close the Storage Definition window to automatically update the storage
database.
16. Click the Create Default Storage icon to save this storage definition as the default
and close the CIM Storage Manager window to return to the CIM Manager main
window.
17. Select Utility Programs | MRP. The CIM MRP window is displayed.
18. From the CIM MRP window perform the following:
1. Select Customer | New Customer. The New Customer window is displayed.
2. In the Name field, enter CUST-A, and if required enter additional information in
the relevant fields.
3. Create two orders for this customer, each one for two parts, but for different
supply dates. (To see a list of parts which can be ordered, open the drop-down list
when the cursor is on the Part Name field. Click to select a part.) For example:
Part Name: BOX Part Name: BOX
Required: 2 Required: 2
Priority: 1 Priority: 1
Due Date: 2 Due Date: 4
19. Save the order by clicking the MRP icon on the toolbar. This runs the MRP
program, which creates a Manufacturing Order.
20. Select the Manufacturing Order tab and select a Manufacturing Order (from the list of
numbers), and click MO to submit the manufacturing order. This creates an

A-Plan (production work order) for the order.
21. Close the CIM MRP window.
22. Select Utility Programs | Report Generator. The CIM Report Generator window is
displayed.
23. From the CIM Report Generator window perform the following:

Virtual CIM Setup
1. From the reports list select the Part Definition report and click the Print Report
icon to display the report on the screen. You may also select Subparts, Process,
Analysis and A-Plan to view other reports.
2. Close the Reports Generator window.
24. From the CIM Manager toolbar click the CIM Modes icon. From the displayed
Modes dialog box, perform the following:
1. In the CIM Mode area, select Simulation mode and enter the simulation speed.
For example x5.
2. In the Remote Graphic Display area, select No. This option refers to the external
graphic display only; the internal graphic display of the CIM Manager is always
active.
3. Click Save to close the Modes dialog box and return to the CIM Manager main
window.
4. Click the Start button to execute (meaning, load the Manufacturing

Order).
5. Click the Run button to activate (meaning, run the production cycle.)
6. Congratulations. Your CIM cell is in operation! Look at the Order View, Device
View, Program View and Pallets View and follow the progress of the production.
7. Acknowledge the messages Part has been Finished. and Order Finished.
8. Close the production by clicking the red Stop button.

25. You will now repeat the production cycle, and view it through the Graphic Display
module.
26. From the CIM Manager toolbar click the CIM Modes icon. The Modes dialog
box is displayed.
27. In the Remote Graphic Display area, select Yes and then click Save. Make sure that you
activate the external Graphic Display (see the last step of this procedure) otherwise the
CIM will run slowly.
28. Click the Reset Storage icon on the CIM Manager toolbar.
29. Click the Graphic Display icon from CIM-1 Group (displayed from your windows
Start menu). The CIM Simulation screen will appear. You will see the CIM cell you
created by means of the Virtual CIM Setup in three different 3D views.
30. Return to the CIM Manager screen and perform the following:
1. Click the blue Start button to execute (meaning, load the Manufacturing
Order).
2. Click the blue Run button to activate (meaning, run the production cycle).
3. You also can see your CIM cell in operation by means of the Graphic Display.

Virtual CIM Setup
9
OpenCIM Device Drivers
This chapter is not applicable for OpenCIM Offline.
Note
This chapter describes the OpenCIM device drivers. Device drivers are interface programs
that translate and transmit messages between the CIM Manager and the various machines
and controllers at CIM stations. It includes the following sections:
Overview of Device Drivers, provides a brief overview of the
OpenCIM device drivers and the devices they control.
Device Driver Control Panel, provides a brief overview of the
device driver control panel that is used for sending commands to the
device.
CNC Device Driver, describes the CNC device driver that controls
various types of CIM machines (lathe, mill and more).
Robotic Device Drivers, describes the robotic device driver that
controls the devices attached to robotic controller (such as, robots,
barcode scanners and more).
Quality Control Device Drivers, describes the quality control
device drivers that control QC devices (such as the laser scan meter)
ViewFlex Device Driver, describes the ViewFlex device driver that
controls the Vision Machine System.
ULS Device Driver, describes the ULS device driver that controls all
operations of the Laser Engraver.
BCR Device Driver, describes the BCR device driver that controls
all operations of the Bar Code Reader.
RFID Device Driver, describes the RFID device driver that controls
all operations of the RFID reader.
PLC Device Driver, describes the PLC device driver that controls
the operation of the conveyor.
Hydraulic Device Driver, describes the hydraulic device driver that
controls the hydraulic station.
Pneumatic Device Driver, describes the pneumatic device driver
that controls the pneumatic station.
Process Device Driver, describes the process device driver that
controls the process station.

Overview of Device Drivers
Device drivers are the link between the CIM Manager and the devices in the CIM cell. The
device drivers are used to perform the following functions:
Relay command and status messages during production between a
device and the
OpenCIM network.
Simulate a device.
Test a device.
OpenCIM device drivers can run on both Station Manager PCs and the CIM Manager PC,
depending on the configuration of the CIM system.
Device Driver Devices Controlled
CNC A single CNC machine.
Robotic Device Driver Devices connected to and controlled by a robot controller;
(ACL or Scorbase) e.g., robot, automatic screwdriver, barcode reader.
Quality Control Device ROBOTVISIONpro, Laser Scan Meter, ViewFlex, Barcode
Drivers reader, RFID reader.
ULS Laser Engraver.
PLC The CIM conveyor.
Hydraulic The hydraulic station
Pneumatic The pneumatic station
Process The process station

Device Driver Control Panel
Device drivers are loaded automatically by the virtual loader, DDLoader.EXE.
This program loads all device drivers from command lines found in the [Loading] section of
the device drivers INI file. Refer to Chapter 12 for more details on the loader program.
All device drivers have the following features:
A Control Panel for manually sending commands to the device and
for viewing status information.
A Virtual Device Driver Status window for displaying status
information, error messages, and responses from the device when
appropriate.
When a device driver is loaded its Virtual Device Driver Status window and its Control
Panel appear on the screen. For example:
.
Figure 9-1: Device Driver Control Panel (ACL)
You must close the status window in order to close the device driver.
The device driver Control Panel is discussed in detail in the section on the ACL device
Note driver. The discussion there is applicable to all other device drivers.

Modes of Operation
Like the CIM Manager, the device drivers can operate in either Simulation Mode or Real
Mode. In addition, Manual Mode allows you to interact with the software and hardware.
In order to operate a device driver (DD) in Real Mode, check the Load column next to the
desired driver(s). Similarly, to operate a device driver in simulation mode, check the
Simulation column next to the desired driver(s).
Figure 9-2: DD Loader

The following table describes device driver modes:
Option Description
Real Mode Normal operating mode. The device driver is ready to communicate with
both the CIM Manager and the physical device (or its controller).
The message Connected OK is displayed after the device driver
successfully receives the first message from the device (either on a serial
port or a PC I/O card).
In Real Mode, all communications between the device and other CIM
entities occur automatically. However, it is also possible to manually
send commands to the device using the Control Panel.
Simulation In Simulation mode, the device driver receives commands as usual from
Mode the CIM Manager and emulates a device by automatically responding
with the appropriate status messages. The device driver does not actually
communicate with the physical device.
The quality control device drivers randomly return either a successful or
unsuccessful status message based on the parameter FailPercent.
All other device drivers always return a successful status message in
Simulation mode.
Manual In Manual mode, the device driver receives commands as usual from the
Mode CIM Manager while you interactively emulate the device using the
device drivers Control Panel. The device driver does not generate status
messages automatically; they are generated only when you manually
make selections from the Control Panel.
In Manual mode the device driver does not actually communicate with
the physical device. (See the specific section about each device driver for
details on how to use the Control Panel to send responses back to the

Option Description
CIM Manager.)
Standalone The Standalone mode enables you to input manager specific commands
Mode and execute them directly to the controller without any intervention from
other system components.
Device Driver Loading Options

Normally device drivers are started from the Loader program that reads device driver
command lines from an INI file. For example:
Load2=..\BIN\ACLDriver.EXE ACLVD1.INI 21 /COM:1 /C
Load3=..\BIN\CNCDriver.EXE CNCVD1.INI 23 /COM:2 /C
If you are activating a device driver in standalone mode, cancel the TCP/IP Network
Messaging between the device driver and the manager. To do so:
From the Device Driver Control Panel, select OPERATION MENU. Select TCP/IP status
and click UNABLE.
Once a device driver has been loaded, you cannot change its control mode. You must exit the
device driver and restart it in the desired mode.
Option Description
Real Mode This mode is the default if no special mode switches are specified on
the command line that invokes the device driver.
Simulation Use the /SIMULATION switch on command line that invokes the
Mode device driver.
Manual Mode Use the /Com:0 switch on command line that invokes the device
driver.
Standalone The Standalone mode enables you to input manager specific
Mode commands and execute them directly to the controller without any
intervention from other system components.
If a device driver is unable to open an RS232 port in order to communicate with its device, it
displays the following message in the Control Mode box:
Cannot Open Com:n
This error message indicates that the device driver could not open the serial port on the
Station Manager PC. Possible causes include:
The port is in use by another application.
The port number is invalid.
One of the serial port parameters is invalid.

CNC Device Driver
The CNC Device Driver interfaces between the OpenCIM system and various types of
machines such as a lathe or milling machine.
It receives command messages from the CIM Manager, adjacent robots, and other CIM
devices. In response, it runs the corresponding CNC script program which operates the
machine. The device driver responds with status messages about the CNC machine to CIM
elements which have registered for these messages.
The CNC Device Driver performs the following functions:
Device Driver Function By Using
Sends commands to a CNC machine the CNC Script Interpreter
Tests and debugs Command Interpreter the CNC Control Panel
programs
Sends CNC status messages to other the OpenCIM Network
CIM elements
Loads G-code programs into a CNC an RS232 connection
machine
The CNC Device Driver controls machines connected in either of the following ways:
A machine connected to an internal I/O controller board in the
Station Manager PC
A machine connected to an ACL controller
An internal I/O board maps 16 CNC control lines to two output ports on the PC. It also maps
16 CNC status lines to two input ports on the PC. These I/O port addresses are stored in the
file CNCVD1.INI.
A CNC machine that receives commands via an RS232 interface can be connected to a serial
port on an ACL controller. You can write an ACL program to control the machine and
activate this program by sending commands to the ACL device driver using the CNC script
language.
Running the CNC Device Driver

This section describes how to run the device driver. It includes the following sections:
Loading the CNC Device Driver
CNC Device Driver Status Window
Generating a CNC Log File
Loading the CNC Device Driver

CNC device drivers are loaded automatically by the DD Loader, DDLoader.EXE. This
program loads all device drivers from command lines found in the [Loading] section of the
local INI file. To manually start a CNC device driver from the Program Manager (e.g. to run
the CNC Control Panel for troubleshooting), select the icon for the appropriate CNC
machine.
The following examples assume that the CNC device driver is being invoked from the
[Loading] section of the CNCVD1.INI parameter file.
For example, to run the CNC Device Driver for CNC machine # 23, use:
Load4=..\BIN\CNCDriver.EXE CNCVD1.INI 23 COM:3

CNC Device Driver Status Window
The Status window appears while a device driver is running. It displays status and error
messages, debug information, and output from the following sources:
CNC script programs
ACL programs
Scorbase programs
Quality control devices
PLC programs
Generating a CNC Log File
The CNC log file facilitates debugging and troubleshooting. It captures the results of each
operation performed by the device driver that are displayed in the Status window. This
information is written to a file called CNC_DeviceID.PRT where DeviceID is the 3-
digit device ID number of the CNC machine (e.g. CNC_023.PRT).
17:21:48.72 PULSBIT( 0x500, 0x0, "00001000", 500 )

17:21:49.33 --- OPEN DOOR ---
17:21:49.44
17:21:49.44 --- DOOR IS OPENED ---
17:21:49.55 WAITBIT( 0x500, "00000010", 10000 )
17:21:49.66 --- Condition is true ---
17:21:56.52 PULSBIT( 0x500, 0x0, "00010000", 500 )
17:21:57.13 --- CLOSE DOOR ---
17:21:57.23
17:21:57.23 --- DOOR IS CLOSED ---
17:21:57.34 WAITBIT( 0x500, "00000100", 10000 )
17:21:57.45 --- Condition is true ---
Figure 9-3: Sample CNC Log File

The log information includes each CNC script command executed, display messages,
OpenCIM network messages received and sent, and error messages. Even messages that
have scrolled off the screen are recorded. Each entry in the log file is time stamped to the
nearest 1/100 of a sec.
The log file is placed in the same directory as the CNCVD1.INI file after the device driver
has been closed.
The log file is saved as ASCII text. You can use any text editor to examine and print its
contents.
Note The log file is overwritten each time you save it. If you want to preserve the previous
contents, rename the file CNC_DeviceID.PRT first.

Downloading G-Code
A CNC device driver downloads a G-code file to a machine in response to a command from
the CIM Manager (in preparation for running a CNC process).
The device driver uses one of the following download mechanisms depending on which you
specify:
A download utility that you supply called from a specified batch file
(recommended)
The built-in downloader of the CNC device driver
This section discusses how to use a utility program that you supply to download G-code.
This method is usually preferable to using the device driver's internal downloader because a
utility program provided by the CNC manufacturer can take advantage of all of a machine's
features (e.g. providing error correction during the download).
The commands required to invoke a machine's downloader are inserted into a DOS batch
file. The last command in this batch file creates a flag file which signals that the download is
complete. The CNC device driver automatically deletes this flag file each time it invokes the
batch file.
To build this batch file and direct the device driver to use it, do the following:
1. Write a batch file named CNC_L.BAT which calls the utility
downloader as shown in the following example:
DLOADG.EXE %1 %2
Procedure ECHO Task Loaded > <%project
Creating a directory%>\WS3\TASK.CNC
Utility for 2. When the CNC device driver calls this batch file, it specifies the
Downloading following two parameters (which appear on the first line of the batch
G-code file above):
The G-code file to download (which includes the full DOS path)
The memory region within the CNC's RAM that stores this
G-code program.
3. Define the following parameter entries in the
[CNCDriverDefinitions] section of the INI file for this CNC
device driver:
Loader = <%project
directory%>\WS3\CNC_L.BAT
TaskLoadedMark = <%project
directory%>\WS3\TASK.CNC
When these parameters are defined, they tell the device driver to use
the specified download utility program instead of its internal
downloader.

The CNC Control Panel
The CNC Control Panel is a feature of the CNC Device Driver that allows you to perform
the following functions:
Run CNC programs interactively.
Control CNC operations by setting bits on the Output Panel.
Read the status of the CNC machine by examining bits on the input
panel.
Figure 9-4: CNC Device Driver Control Panel

This section includes the following sections:
Running CNC Programs Interactively
PC-Input/Output Panel
Output Panel
Input Panel
Program History List
Closing the Control Panel

Running CNC Programs Interactively
The CNC Control Panel allows you to run CNC programs created with the CNC Script
Interpreter and view the results.
To run a Command Interpreter program using the Control Panel, do the following:
1. Determine the parameter(s), if any, that are to be passed into the
program. Type these value(s) in the box labeled CNC Command
Parameters (e.g. 500 for a 500 millisecond delay)
Procedure 2. Use the mouse to scroll through the CNC Command List in order to
Running a Command find a program. Double-click on a program name to run that
Interpreter Program
program.
If the CNC machine is connected to the I/O board in the PC, you can observe the effects of a
program by observing the line indicators in the PC-Inputs and PC-Outputs panels in the
Control Panel. In addition, status messages and instructions generated by the program appear
in the Status window.
PC-Input/Output Panel
To display the PC-Input/Output Panel, select from the main menu Operation | Input/Output.
Output Panel
The Output panel allows you to observe and set the state (On or Off) of 16 CNC control
lines. Control lines may be hard-wired to specific CNC functions. Alternatively, the CNC
machine may be configured to activate a certain G-code program associated with a control
line. Check the documentation of your CNC machine for specifics on the use of each control
line.
The PC-Output panel allows you to set CNC control lines on and off by clicking bits in the
appropriate output port. The layout of the panel reflects the way the control lines are mapped
to bits in two designated PC output ports. By using a mouse to click on the bits in the panel,
you can:
Toggle the state of a control line.
Pulse a control line by clicking its bit, waiting the desired interval,
and clicking it again to restore it to its original state.
Input Panel
The Input panel allows you to observe the state (On or Off) of 16 CNC status lines. Status
lines may be hard-wired to specific CNC components. Alternatively, the CNC machine may
use a G-code program to set the state of a status line. Check the documentation of your CNC
machine for specifics on the meaning of each status line. The layout of the panel reflects the
way the status lines are mapped to bits in two designated PC input ports.
The PC-Input panel displays the state of CNC status lines. It cannot be used to change the
value of a status line. Only the CNC machine can change the value of a status line.

Program History List
You can view a list of programs that were run by clicking on the drop-down list box labeled
Task History.
Closing the Control Panel
It is a good idea to close the Control Panel in order to prevent others from tampering with it
while the CNC machine is active. Use one of the following standard Windows methods for
closing a window:
1. Double-click the control bar in the X button of the Control Panel window.
2. Click the control bar and select Close.
3. Press [Alt + F4] while in the Control Panel window.
You should always close the Control Panel if you are going to leave the CIM
Warning! unattended. Otherwise someone might cause damage if they inadvertently
activate a machine (such as a CNC machine) by making selections on the
Control Panel (e.g. by clicking on the Output panel or by selecting a task
which starts the machine).

The robotic device driver relays messages between the OpenCIM network and the devices
attached to a robotic controller such as:
An Intelitek robot
An automatic screwdriver
A barcode scanner
An X-Y table
ASRS-36
ASRS-36U
This device driver receives command messages from the CIM Manager and adjacent CNC
machines (for ACL only). In response, it runs the corresponding robotic program. The
robotic device driver communicates with the controller using an RS232 port on the Station
Manager PC.
The robotic device driver performs the following functions:
Activates robotic programs.
Receives status messages from robotic programs and relays them to a
CIM entity.
Allows you to interactively operate robots and peripheral devices
attached to a robotic controller.
Allows you to test and debug robotic programs by sending
commands from the Control Panel.
Emulates a robot in Simulation mode.
The primary robotic command is to run a set of pick-and-place programs which direct a
robot to move a part from one location to another at a station. Robotic ACL or Scorbase
programs can also direct a robot to perform other tasks such as assembly operations or they
can control peripheral devices such as the Rotary Table.
Robotic Device Drivers User Interface
The robotic device drivers user interface enables you to perform the following functions:
Simulate a robot.
Issue robotic commands interactively.
Debug pick-and-place programs by running them interactively.
Test a robot and its positions and programs by issuing a series of
pick-and-place commands stored in file.
Create a file of pick-and-place commands.
Robot Operation
The ACL and Scorbase device drivers contain different interfaces for operating the robot,
each of which is described in the following sections.
Scorbase Device Driver
ACL Device Driver
Scorbase Device Driver

Since the Scorbase device driver is part of the Scorbase software, you can use Scorbase
software functionality in order to operate the robot. The Scorbase device driver window (for
OpenCIM) is displayed, as follows:

Figure 9-5: Scorbase Device Driver (for OpenCIM)
You can select one of the following modes: Online Mode, Simulation Mode (Automatic or
Manual) and Standalone Mode. For further details refer to Control Modes for the Robotic
Device Driver in the following section.
Reloading Last Project at Startup

When loading the Scorbase device driver for the first time, perform the following procedure
enabling you to relaod the last project the next time you activate the Scorbase device driver.
To reload the last project at startup:
1. From your windows start menu, click the Loader icon of your workstation
. The CIM DDLoader window is displayed.

2. Ensure the Load column is selected for the Scorbase device driver and click the
Load Selected Drivers icon. The Scorbase device driver window is displayed.
Figure 9-7: Main Scorbase Device Driver Window

3. From the File menu select Open Project. The Load Project window is displayed.
4. Select the required project in accordance with your OpenCIM workstation configuration
and click OK. The project is displayed in the main window.
From the Options menu, select Reload Last Project at Startup. The next time you access
the Scorbase Device Driver, this project will automatically be displayed.
ACL Device Driver

You can use the ACL device driver, as a limited terminal to send commands to a controller.
Commands that you type in the Send to Controller field are sent out the PCs serial port
when you press Enter. Responses from the controller are displayed in the status window of
the device driver. This capability is useful for testing and debugging individual ACL
programs. The ACL device driver window is displayed, as follows:
Figure 9-8: ACL Device Driver

Control Modes for the Robotic Device Driver
The robotic device driver, like all other device drivers, can pass actual messages or can
generate simulated messages. In Real Mode, the device driver relays messages between the
OpenCIM system and a robotic controller. In one of the simulation modes, the robotic device
driver can be used to emulate a robot or to test a robot.
The following list shows the messages that can appear in the Control Mode box on the
Control Panel. In each mode, the device driver treats command messages the same whether
they originate from the CIM Manager or from selections you make from the device driver's
Control Panel.
The activation examples show command lines from the Loader's INI file used to start the
device driver in the designated mode. Bold command line switches highlight the specific
switch used to invoke that mode.
Option Description
Real Mode Normal operating mode. The device driver relays command messages to the robotic
(Online) controller from the CIM Manager, CNC machines, etc. In turn, it broadcasts status
messages from the controller to the OpenCIM network.
Command line for ACL: ACLDriver.EXE ACLVD3.INI 31 /COM:1
Command line for Scorbase: /O /I=ACLVD1.INI /N=11
/CIMDD_ONLINE
Real Mode: The robotic device driver shows that it has received the first message from the
Connected OK robotic controller on the serial port.
Cannot Open Com:n The robotic device driver could not open its serial port on the Station Manager PC.
Simulation Mode The robotic device driver receives commands as usual but emulates a robot and a
(Automatic) barcode reader by generating status messages automatically.
In this mode, the device driver does not actually communicate with the robotic
controller; only with the CIM Manager (and other devices that send it commands).
/SIMULATION
Command line for Scorbase:/I=ACLVD1.INI /N=11
/CIMDD_SIMUL_AUTO
Simulation Mode The robotic device driver receives commands as usual but only generates status
(Manual) messages when you double click on a line in the Task History box.
In this mode, the device driver does not actually communicate with the robotic
controller; only with the CIM Manager (and other devices that send it commands).
Standalone Mode The Standalone mode enables you to input manager specific commands and execute
them directly to the controller without any intervention from other system
components.
The ACL and Scorbase device drivers enable controlling the robot from both the
Warning! OpenCIM Manager and Station PC simulataneously. This is useful for
development and testing procedures of the robotic programs. However,it can be
dangerous when operating the CIM system in online mode. Therefore you should
always close the Control Panel to prevent others from tampering with it when the
robot is truned on. Otherwise someone might cause damage if they inadvertently
activate the robot by making selections from the robotic device driver window
(for example, by clicking on the Play From P/P File button) .

Task History List
The Task History box shows the last several commands sent to the controller. You can scroll
the background to see commands that have scrolled off the screen.
Testing Pick-and-Place Commands
The pick-and-place buttons of the Control Bar allow you to send commands to the robot to
move parts around the station. (These options are available in stand alone mode only when
using the Scorbase device driver.)
A brief description of the each these pick-and-place buttons is described in the following
table:
Option Description
Enter P/P Command Allows you to manually send a pick-and-place command to the
robot instead of the command being sent by the CIM Manager.
Selecting this button presents you with the Run Pick-and-Place
dialog box .This dialog box requests the following six
parameters:
Part ID - Number of the part/template to be moved
(template = 0)
Source ID - Device ID of source location where the robot is
to pick up the part/template. Located next to the Source
ID field is a drop-down list that allows you to select the
Source ID by name and not by index.
Source Index - Compartment number if source location is
divided into cells. Located to the right of the Source
Index field is another field that displays the number of
the compartment.
Target ID - Device ID of target location where the robot is
to place the part/template. Located next to the Target ID
field is a drop-down list that allows you to select the
Target ID by name and not by index.
Target Index - Compartment number if target location is
divided into cells. Located to the right of the Target
Index field is another field that displays the number of
the compartment.
Note - Can be used to send special instructions to assembly
programs or user-developed programs.

Option Description
Note
The names and the range that appear in the Pick-and-Place
dialog box are taken from the INI file used by this device driver.
Figure 9-9: Run Pick-and-Place Dialog Box

Play from P/P File Begins executing a series of pick-and-place commands stored in
a special text file designated for this robot, ACL_xxx.PNP. The
xxx is the device ID of this robot (found in the title bar of the
Control Panel). These commands are sent one at a time.
This file can be used to thoroughly test a robots ability to
retrieve and deliver parts from every device at a station. Pick-
and-place commands involving every device can be stored in the
pick-and-place file. Playing this file would then allow you to
observe if the robot was able to properly access every device.
% Complete from This display activates when you select the Play button. It shows
P/P File what percentage of the pick-and-place file has already been
executed.
Save P/P Cmds Saves a pick-and-place text file containing all pick-and-place
commands found in the Task History box. This file is saved in
the current working directory under the name ACL_xxx.PNP.
Close P/P File Terminates the playback of a pick-and-place file.

A quality control device driver interfaces between the OpenCIM network and a quality
control device such as the ROBOTVISIONpro Laser scan meter.
A device driver communicates with a QC device using an RS232 connection.
Figure 9-10: A QC Device Driver Passing Messages to and from a QC Device

The QC device driver receives a command message from the CIM Manager specifying the
type of quality control test to run. It then performs the following steps:
1. Activates the specified test on the QC device (e.g. a Scan command for a
ROBOTVISIONpro system).
2. Receives the test result from the device.
3. Compares the result to a range of acceptable values specified in the command message.
4. Sends a pass/fail status message back to the CIM Manager.
If the result is fail, the CIM Manager:
Disposes of the defective part as specified by an ONFAIL process in the Part Definition
table.
Automatically reproduces the part.
Each QC test is defined as a separate process in the Machine Definition module. The test
type and acceptable range of test results may be specified in the Parameters field of the Part
Definition table.
If the quality control device is connected to an ACL controller (e.g. a barcode reader), the
name of the ACL program that activates this device should be specified in the Program field
of the Machine Process table in the Machine Definition module.
It is possible to use a robot as a quality control device. You can write special ACL
programs which perform quality control tests such as:
Tips
Have a robot try to place a part in a mold. If the part is too big, you can detect the
collision. If it is too small, you can detect free play when the robot tries to move
the part after it has placed it in the mold.
You can measure the dimensions of a part by reading the span of the robot's
gripper when it is holding the part.
The following table shows how to set up test parameters for each type of QC device driver:

QC Device Test Type Acceptable Range of Values
ROBOTVISIONpro The system scans a part The number of objects the
Camera looking for an object(s) that ROBOTVISIONpro system
was defined as a Pattern ID should find. If the minimum and
in the ROBOTVISIONpro maximum values are the same,
software. (e.g. Are three the system must find this exact
screws in place?) number in order for the part to
pass the test.
Laser Scan Meter Checks the diameter of a Minimum and maximum values
cylinder. Test type = 1. represent the tolerance
surrounding the desired diameter.
There is a customized version of the quality control device driver for each of the quality
control devices listed above. Since these three device drivers are essentially similar except
for the internal message format used to communicate with the quality control device, this
section discusses the operation of all three. In this discussion, these device drivers are
interchangeable and are referred to simply as the quality control device driver. All QC device
drivers look the same to the CIM Manager, i.e. it sends the same type of command
message to each type and receives the same type of pass/fail status message from each.
A quality control device driver performs the following functions:
Activates a test on a quality control device.
Receives status messages from a quality control device and sends
them to the CIM Manager.
Allows you to test and debug a quality control device by sending
Emulates a quality control device in Simulation mode.

The QC Control Panel
The QC Control Panel is a feature of the QC device driver. It allows you to perform the
following functions:
Determine the control mode the device driver is running in.
Simulate the test results from a QC device.
Monitor test results in real - time.
Test the QC device by manually issuing command messages to it and
observing the results.
Figure 9-11: Control Panel for a Quality Control Device

Driver
Control Modes for Quality Control Device Drivers

A QC device driver, like all other device drivers, can pass actual messages or can generate
simulated messages. In Real Mode, the device driver relays messages between the OpenCIM
system and the quality control device. In one of the simulation modes, the QC device driver
can be used to emulate a quality control device or to test a device. For more details, refer to
Device Driver Loading Options.
The table below shows the messages that can appear in the Control Mode box on the Control
Panel. In each mode, the device driver treats command messages the same whether they
originate from the CIM Manager or from selections you make from the device driver's
Control Panel.

The activation examples show command lines from the Loader's INI file used to start the
device driver in the designated mode. Bold command line switches highlight the specific
switch used to invoke that mode.
Option Description
Real Mode Normal operating mode. The device driver relays command messages to
the QC device from the CIM Manager. In turn, it broadcasts pass/fail
status messages from the device to the OpenCIM network.
Activation: LSMDriver.EXE LSMVD1.INI 13 /COM:2
Real Mode: The QC device driver shows that it has received the first message from
Connected OK the QC device on the serial port.
Cannot Open The QC device driver could not open its serial port on the Station
Com:n Manager PC.
Simulation The QC device driver receives commands as usual but emulates a quality
Mode control device by generating pass/fail status messages automatically
based on the value in the Fail % field.
In this mode, the device driver does not actually communicate with the
QC device; only with the CIM Manager.
/SIMULATION
Manual Mode The QC device driver receives commands as usual but only generates
pass/fail status messages when you click on the Success or Fail buttons.
In this mode, the device driver does not actually communicate with the
QC device; only with the CIM Manager.
Standalone The Standalone mode enables you to input manager specific commands
Mode and execute them directly to the controller without any intervention from
other system components.

Controlling a QC Device from the Control Panel
The buttons on the Control Panel allow you to send commands to the quality control device
and status messages to the CIM Manager. These buttons are described below.
Option Description
Check Activates a test on the quality control device. This button only functions
in Real Mode. It is useful for testing communications with the quality
control device. The response from the device appears in the device
driver's Status window.
This button resends the last command message from the CIM Manager as
shown in the fields Low, High, and Type described below. If no
command message has yet been received, the default values are:
Type = 1, High = 0, Low = 0
Success Generates a status message to the CIM Manager indicating that a part
passed its quality control test. Used in Manual mode.
Fail Generates a status message to the CIM Manager indicating that a part
failed its quality control test. Used in Manual mode.
The following fields on the Control Panel show the parameters associated with the last
command that was sent to the quality control device. These values are used when you select
the Check button (described above) to manually send a command to the device.
Option Description
Low The minimum acceptable test value.
High The maximum acceptable test value.
Type An ID number specifying which sort of quality control tests the
device should perform.
The Fail % field allows you to control how the device driver responds when it is operating in
a simulated mode:
Option Description
Fail % Used only in Simulation mode. Randomly determines how often the
simulated test result will be Success or Fail (0% = always
successful, 100% = always failure). Pass/fail results are generated
randomly.
The default failure percentage is read from the parameter
SimulationFailPercent in the device driver's INI file.
Changing this value on the Control Panel affects the current session
but does not save the new value to the INI file.

QC Device Settings
Each quality control device driver uses a duplicate set of INI file parameter settings shown in
the following figure(Figure 9-12). These settings relate to:
Format of a quality control log file.
Running the device driver in Simulation mode.
RS232 communication settings.
Appearance of the device driver's Control Panel on screen.
When you want to simulate the operation of a QC device, the QC device driver provides
simulated test results to the CIM Manager stating whether a part passed or failed a QC test.
The parameter SimulationFailPercent allows you to set the default failure
percentage that a QC device driver uses when running in Simulation mode.
The following sections discuss particular settings for each type of quality control device
driver.
ROBOTVISIONpro Settings
The ROBOTVISIONpro device driver works best with v2.3 or later of the
ROBOTVISIONpro software. Use the parameter Snap = Yes to indicate version 2.3 or
later.
You can use the Frame parameter to specify the frame area in the camera's field of view
where the ROBOTVISIONpro system should scan for objects.
When you train the ROBOTVISIONpro to recognize a new object, the ROBOTVISIONpro
software assigns a unique Pattern ID. Use this number as the test type when setting up the
Parameter field in the Part Definition table.
Laser Scan Meter Settings
A laser scan meter is a straightforward quality control device that performs only one type of
test. Use a test type of 1 for this device when entering values in the Parameter field of the
Machine Process table or the Part Definition table.
[General]
CimSetupPath=C:\OPENCIM\SETUP\SETUP.CIM
[LSMDriverDefinitions]
QCReport = Yes
QCReportTemplateFile = VC2_QC.INI
QCReportFileName =
QCReportFileMarker =
QCReportFileDeleteOnStart =
SimulationFailPercent = 20
BaudRate=9600
Parity=None
DataBits=8
StopBits=1
XonXoff=No
MainWindowBkgndColors=40,150,100
MainWindowTextColors=100,50,200
Figure 9-12: Sample INI File Settings for a Laser Scan Meter

ViewFlex Device Driver
The ViewFlex Device Driver interfaces between the OpenCIM network and the Vision
Machine System as a quality control device.
Each quality control test is defined as a separate process in the Machine Definition module.
The quality control test consists of three parts:
File the Script File (.bas) that contains the Program (Function) to be
executed.
Program the Function from the File that returns the results of the
quality control process to the OpenCIM Manager as Pass/Fail or
Error.
Fail %. Simulate test results (only in Simulation Mode) by
determining the Pass/Fail according to the percentage of failure that
was input.
The ViewFlex Device Driver performs the following functions:
Activates a test on the Vision Machine System.
Receives status messages from the Vision Machine System and sends
to the OpenCIM Manager. (OpenCIM Messages in the ViewFlex.)
Allows you to test and debug the Vision Machine System by sending
commands from the Windows dialog box.
Emulates the Vision Machine System in Simulation mode.
Adjustments
Adjustments can be performed ViewFlex.ini files. Each of which is described below.
User Interface
Figure 9-13: ViewFlex Control Panel
Control Modes
The control modes that the ViewFlex Device Driver can run in are:

On-Line (Real): Allows the ViewFlex Device Driver to wait for the following
commands from the OpenCIM Manager: Snap, Load Script, Execute Program
Script, and Send Results.
Manual: Allows you to test the ViewFlex Device Driver by manually issuing the
commands Pass/Fail and observing the results.
The following buttons are available only in Manual Mode, after a request from the CIM
Manager, has been issued:
Option Description
Send Pass.
Send Fail.
Simulation: Allows you to simulate test results by determining the

Pass/Fail according to the percentage of failure programmed into the
CIM Manager.
Debug: Allows you to inspect every step of the script running the
ViewFlex Device Driver, by simulating what will happen when in
Real Mode.
The following buttons are available only in Debug Mode:
Option Description
Open File: loads the script.
Run Script: runs the selected script.
Step-By-Step: runs each command line of the script individually.
Sample Script
A model is the pattern for which you are searching, and the image from which it is extracted.
The following script is a sample for testing Pass/Fail models. The program attempts to find
the x object (X.mod). If found, Fail is sent (QCR="Fail"). If the object is not found, the
program attempts to find the v object (V.mod). If found, Pass is sent (QCR="Pass"). If
neither is found, Error is sent (QCR="Error").
Attribute VB_Name = "Module1"

Function QCR() As String
Dim NumberFound As Integer
Snap1_1$=Insptr.ImgGetCur
Insptr.ImgSetCurrent Snap1_1$, R_Def$, ALL_BANDS
I_IMAGE16$ = Insptr.ImgConvertType(TO_8U)
Insptr.ImgSetCurrent I_IMAGE16$, R_Def$, ALL_BANDS
B_V_BLOB1$ = Insptr.BlobLoad("O:\ER14PRO_ASSEMBLY\WS3\Viewflex\V_CHECK.bst")
Insptr.BlobSetCur B_V_BLOB1$
Insptr.BlobCount
NumberFound=Insptr.BlobCount
Debug.Print NumberFound
If NumberFound=1 Then
QCR="Pass"
Else

QCR="Fail"
End If
Insptr.CloseAll
End Function

ULS Device Driver
The ULS device driver operates the ULS Laser Engraver. In the same way that the CNC
device driver controls all operations of a CNC machine, the ULS device driver controls all
operations of the Laser Engraver.
The ULS device driver communicates with the Laser Engraver via parallel and RS232 links.
It uses the parallel connection in order to download the appropriate engraving program
(CorelDraw or Freehand file) to the device. The serial RS232 is used to establish
communications between the laser machine and the ULS device driver so that programs from
the laser machines memory can be selected and messages transmitted to and from the device
driver.
When a part is to be placed on the laser table, the CIM Manager sends a message to the
device to descend to the lowest level and then rise to the loading level. The robot always
picks & places a part from/to the same level.
Warning!
Do not place any objects in the laser machines front cabinet. When the table descends to its
lowest level, it could crash into objects that may have been placed there.
Downloading Print Files

The laser has two connectors at the back: a 9-pin connector from the device driver, and an
LPT port for connecting to the computer from which the CorelDraw or Freehand files are
downloaded.
The laser has two methods of file storage: one file saves only one file to the memory and
when a new file is downloaded it replaces the old one; when multiple files are stored in the
laser memory, each file is numbered sequentially according to the download order.
Warning!
Working with multiple files in on-line mode could cause the wrong file to be activated.
In one file mode, the fileload.bat file enables the CIM Manager to automatically download
the specific file that is required for the process and later activate other files as ordered by the
CIM Manager.

User Interface
The Laser Engraver interface enables you to perform the following:
Download a file to the laser machine.
Select a file for engraving.
Delete all engraving programs from the laser machine.
Display the properties of the communications port.
Create a log file of all the messages sent during a session.
Specify the TCP/IP status between the CIM Manager and the device
driver.
The device driver can be in one of three states: Ready (yellow), Disabled (red), Working
(green).
Figure 9-14: ULS Device Driver (On Line Mode)

Setting the Zero Point
When you activate the ULS device driver, you are reminded to set the machines Z axis zero
point.
At this point, the lasers focal length should always be 2 inches. This ensures that the laser is
focused and produces maximum efficiency.
To manually set the zero point:
1. Press the Z button from the main menu on the machine or from the file display menu.
2. Select the Focal Length option.
3. Place the gauge on the table (if a template is always used, place the gauge on the
template).
Warning! To prevent impact, be careful not to raise the table with the gauge directly
under the lens carriage.
4. Raise the table carefully to the position where the upper chamfered part of the gauge lies
firmly against the side of the focus lens carriage.
5. Continue raising the table to the point where the gauge tilts outwards.
6. Gently lower the table to the exact point where the gauge straightens, i.e., it is aligned
with the side of the carriage. This is the zero point of the laser engraver and the
loading/unloading position of the robot.
7. Select the Set Focal Length option and confirm to set the zero point.
8. Once you have set the zero point, click OK in the ULS device driver to display the
Laser Engraver Device Driver window, as shown in User Interface.

Control Modes
Like all the device drivers, the ULS device driver can operate in Real, Simulation and
Manual modes; it can also be operated in standalone mode.
Option Description
the Laser Engraver from the CIM Manager. In turn, it broadcasts
start/finish/end status messages from the device to the CIM Manager.
Figure 9-15: Laser Engraver Device Driver - On Line Mode

In the CIM Manager Part Definition, the user specifies the name of the
engraving program as the filename and the Z-axis as the parameter.
The current Z-axis is displayed during operation.
Simulation The device driver emulates Real Mode by communicating with the CIM
Mode Manager. The Laser Engraver is disabled in this mode.
Figure 9-16: Laser Engraver Device Driver - Simulation Mode

Manual Mode In this mode, each command received from the CIM Manager (displayed
in the Action field) must be confirmed by the user (click Do).
Figure 9-17: Laser Engraver Device Driver - Manual Mode

Standalone In this mode, the user is in direct control of the laser machine without any
Mode interference from the CIM Manager. It is therefore the users responsibility
to verify that the laser is operational.
Figure 9-18: Laser Engraver Device Driver - Standalone Mode
The button can be pressed at any stage during the operation.

BCR Device Driver
The BCR device driver operates the Bar Code Reader. In the same way that the CNC device
driver controls all operations of a CNC machine, the BCR device driver controls all
operations of the Bar Code Reader.
The BCR device driver communicates with the Bar Code Reader via parallel and RS232
links.
User Interface
The BCR device driver interface is accessed from the CIM DDLoader window, as described
in the following procedure.
Figure 9-19: BCR Device Driver

To access the BCR device driver user interface:
1. Select the Loader icon of the workstation where the BCR device driver is
installed. The CIM DDLoader window is displayed, as shown in Figure
9-2: DD Loader .
2. To operate the device driver in Real Mode check the Load column of the
BCRDRIVER. To operate the BCR device driver in Simulation mode check the
Simulation column of the BCRDRIVER and then click the Load Selected Drivers
icon to load the BCR device driver software. The various modes of operation are
described in the following section.

Control Modes
Like all the device drivers, the BCR device driver can operate in Real, Simulation and
Manual modes. It can also be operated in Standalone mode.
the Bar Code Reader from the CIM Manager. In turn, it broadcasts
start/finish/end status messages from the device to the CIM Manager.
Figure 9-20: BCR Device Driver (Real Mode)

To operate the BCR device driver in Real Mode:
From the Control Mode drop down list, select Real Mode. The
result is displayed in the Barcode Scan Result area.

Mode Manager. The Bar Code Reader is disabled in this mode.
Figure 9-21: BCR Device Driver (Simulation Mode)

To operate the BCR device driver in Simulation Mode:
1. From the Control Mode drop down list, select Simulation Mode.
2. In the Barcode Operation area enter the failure rate percentage.
For example, enter 50 to randomly determine a 50 percent failure
rate. (meaning, 50 percent of the parts will pass the BCR test and
50 percent will fail).

Manual Mode In this mode, the Bar Code Reader recives commands as usual from the
CIM Manager, but only generates Pass/Fail status messages when you
click on the Pass or Fail buttons.
Figure 9-22: BCR Device Driver (Manual Mode)

To operate the BCR device driver in Manual Mode:
1. From the Control Mode drop down list, select Manual Mode.
2. Select Pass to indicate the part has passed the BCR test or Fail to
indicate the part has failed its BCR test.

Standalone In this mode, the user is in direct control of the Bar Code Reader device
Mode without any interference from the CIM Manager. It is therefore the users
responsibility to verify that the Bar Code Reader Device is operational.
Figure 9-23: BCR Device Driver (Standalone Mode)

To operate the BCR device driver in Standalone Mode:
1. From the Control Mode drop down list, select Standalone Mode.
2. Select Barcode On to activate the barcode reader.
3. Select SCAN Barcode to scan the part in order to identify the
Template Type or Template ID, as required. The result is
displayed in the Barcode Scan Result area.
4. Press Barcode Off at any time to deactivate the barcode reader.

RFID Device Driver
The RFID device driver communicates with the RFID Reader and the CIM Manager.
The RFID device driver connects to the RFID Reader via an RS232 cable. For computers
without a RS232 port, a USB to RS232 adapter may be used.
In order to use the RFID reader with OpenCIM, Template IDs must be assigned to RFID tags
using the RFID Device Driver. For more information, refer to the subsection How to Assign
a Template ID to an RFID Tag, on page 7-25.
User Interface
The RFID device driver interface is accessed from the CIM DDLoader window, as described
in the following procedure.
Figure 9-24: RFID Device Driver

To access the RFID device driver user interface:
1. Select the Loader icon of the workstation where the RFID device driver is
installed. The CIM DDLoader window is displayed, as shown in Figure
9-2: DD Loader .
2. To operate the device driver in Real Mode check the Load column of the
RFIDDRIVER. Then click the Load Selected Drivers icon to load the RFID
device driver software. The various modes of operation are described in the following
section.

Control Modes
Like all the device drivers, the RFID device driver can operate in Real, Simulation and
Manual modes. It can also be operated in Standalone mode.
Real Mode Normal operating mode. This is the default Driver mode. The device driver
relays command messages to the RFID Reader from the CIM Manager. In
turn, it broadcasts a QC result message to the CIM Manager.
Figure 9-25: RFID Device Driver (Real Mode)

To operate the RFID device driver in Real Mode:
From the Control Mode drop down list, select Real. A <Real Mode>
message is displayed in the Open CIM Messages area.
Mode Manager. Communication with the RFID Reader is disabled in this mode.
Figure 9-26: RFID Device Driver (Simulation Mode)

To operate the RFID device driver in Simulation Mode:
1. From the Control Mode drop down list, select Simulation.
The RFID Operation area is updated with the failure rate percentage
that is defined in the Machine Definition utility. For example, 50
indicates a 50 percent failure rate. 0.0.0.

Manual In this mode, the Device Driver receives commands from the CIM Manager,
Mode but only generates Pass/Fail status messages when you click on the Pass or
Fail buttons.
Figure 9-27: RFID Device Driver (Manual Mode)

To operate the RFID device driver in Manual Mode:
1. From the Control Mode drop down list, select Manual.
2. Select Pass to indicate the part has passed the RFID test or Fail to
indicate the part has failed its RFID test.
Standalone In this mode, the user is in direct control of the RFID Reader device without
Mode any interference from the CIM Manager. It is therefore the users
responsibility to verify that the RFID Reader Device is operational.
Figure 9-28: RFID Device Driver (Standalone Mode)

To operate the RFID device driver in Standalone Mode:
1. From the Control Mode drop down list, select Standalone.
2. Pass an RFID tag in front of the RFID reader. The reader will sound
a beep and an entry for the RFID tag will be added to the RFID
device log in the RFID Device Driver.

PLC Device Driver
The PLC device driver relays messages between the OpenCIM network and the
programmable logic controller which controls the operation of the conveyor. These messages
pertain to the movement of pallets on the conveyor.
This device driver runs on a PLC Manager PC which is usually designated as workstation
99. This PC is connected to the PLC via an RS232 link.
The PLC device driver:
Receives a command message and tells a PLC control program to
execute the corresponding function.
Receives status messages from PLC control programs and broadcasts
them on the OpenCIM network.
Allows you to test and debug PLC control programs by sending
Emulates pallets traveling on a conveyor in Simulation mode.
The PLC continually broadcasts the status of pallets on the conveyor as they move past
stations. This flow of status messages enables you to see a real-time display of the conveyor
in the Graphic Tracking module or on the Control Panel of the PLC device driver.
You can manually rearrange pallets on the conveyor while the CIM is running. However, if
you manually change a pallets payload, an error will eventually result since the payload in
the CIM Managers database will no longer correspond.
The PLC operates in a demanding real-time environment. It tracks the status and destination
of every pallet on the conveyor without requiring constant communication with the CIM
Manager. Each time a pallet arrives at a station, the PLC functions autonomously to stop the
pallet; identify it; decide if this pallet is needed at this station, and if so, alert the CIM
Manager. This sequence of events is continuous and is multiplied by the number of stations
in the CIM.
In order to give the best possible response time, the PLC functions independently of the CIM
Manager. When the CIM Manager needs a pallet at a station, it sends a command message to
the PLC. The CIM Manager then waits for the PLC to inform it that the pallet has arrived.
The PLC holds the pallet at the station until the CIM Manager sends a release command.
The CIM Manager does not track the continuous flow of pallets as they move around the
conveyor. As with other devices, the CIM Manager specifies what it wants but does not get
involved in the details of how to carry out the request.

PLC Messages
The PLC device driver receives the following command messages from the CIM Manager
and relays them to the PLC. These commands correspond to the buttons on the PLC Control
Panel.
Commands
to the PLC
Device Description
Driver
GetFree Orders the PLC to stop the next empty pallet at the specified
station. Used when a part (or empty template) needs to be picked
up at this station (including the ASRS station).
Release The CIM Manager allows a needed pallet continue on the
conveyor if the station is busy when the pallet arrives. Releasing
the pallet prevents a traffic jam on the conveyor. This can occur if
the robot that loads/unloads pallets is busy or if a pallet cannot be
unloaded because the buffers are full. The pallet's destination
remains unchanged.
Pallet Carrying Template - If the pallet's destination = this
station, it will be stopped the next time it comes around to this
station.
Empty Pallet - If the pallet's destination = 99, the next empty
pallet to arrive at this station will be stopped.
Deliver Orders the PLC to stop the specified pallet at the specified station.
The CIM Manager issues this command in order to assign a
destination to a pallet at the time it is loaded with a template
(i.e. every pallet carrying a template should have a destination).
Free Release a pallet that was unloaded at this station. Flag it as
available (i.e. destination = 99). This command is similar to
Release except that the pallet's destination is changed to 99 to
indicate that the pallet is empty and available.
The following status messages from the PLC are forwarded to the CIM Manager by the PLC
device driver:
A pallet carrying a template for this station has arrived.
An empty pallet has stopped to pick up a template.
If the Graphic Tracking module is running, a Pass message can be generated each time a
pallet passes through a station where it was not needed. These messages keep the real-time
conveyor display updated. However, if the frequency of these messages slows down the
system, you can improve performance by disabling them.

The following sample scenario demonstrates the role of the PLC device driver in relaying
command and status messages between the CIM Manager and the PLC. This scenario
assumes that a part is being picked up from the ASRS station 1 and delivered to production
station 2.
Message Description
(Command messages in bold)
GetFree The CIM Manager sends a command to the PLC to
Stop an empty pallet at stop the next empty pallet that arrives at the specified
station 1 station.
Empty pallet has arrived at The PLC responds with a status message when an
station 1 empty pallet has arrived.
Deliver After the ASRS robot loads a part template on the
Stop loaded pallet at station 2 pallet, the CIM Manager sends a command to the
PLC specifying that the PLC should stop this pallet at
station 2. The PLC releases the pallet from the ASRS
station 1.
Loaded pallet has arrived at The PLC sends a status message to the CIM Manager
station 2 when the pallet arrives at the station.
Free After a robot removes the template from the pallet,
Allow empty pallet to leave the CIM Manager sends a command to the PLC to
station 2 release this empty pallet. This empty pallet is now
tagged as available (i.e. destination = 99). It
circulates on the conveyor until the CIM Manager
sends a request to the PLC for an empty pallet (return
to step 1).

PLC Control Panel
The PLC Control Panel is a feature of the PLC device driver. It allows you to perform the
following functions:
Monitor the location and destination of every pallet on the conveyor.
Test the PLC and conveyor by manually issuing command messages to the PLC.
Simulate the movement of pallets on the conveyor.
Determine the control mode the device driver is running in.
Figure 9-29: PLC Control Panel

Pallet Status Display
The Pallet Status display shows the status, location, and destination station for each pallet on
the conveyor. This display is updated each time the PLC stops a pallet and identifies it at a
station.
A code of 99 indicates an empty pallet that is available for use, i.e. it has no destination. The
status of a pallet (listed in the Status column) can be one of the following:
Pallet Status Description
Run This is the default condition for all pallets when the CIM starts up. This
status remains in effect until a pallet passes its first station and an update
message from the PLC is received. If the Run status for a pallet never
changes, this indicates that the pallet is not currently present on the
conveyor.
The Run status can also be assigned as a result of a Free command. The
pallet retains this status only until it reaches the next station at which time
it changes to either Pass or Arrive.
A pallet with a Run status has a destination of 99, i.e. no destination has
been assigned to it.
Arr Assigned to an empty pallet that is being held at a station waiting to be
(Arrive) loaded. The pallet is stopped at the station as a result of a GetFree
command.
Stp Indicates that a loaded pallet has arrived at its destination.
(Stop)
Rls A pallet required by this station has arrived, but the station is too busy to
(Release) deal with the pallet. Usually this occurs as a result of a busy robot or
when all the stations buffers are full.
Rather than hold up traffic on the conveyor, the pallet continues on the
conveyor. If the pallet is carrying a template for this station, it will be
stopped the next time it comes around. If the pallet is empty, the next
empty pallet will be stopped in its stead.
The Release status changes to either Pass or Arrive when the pallet
reaches the next station.
Pss Indicates that the pallet just passed through a station that was not its
(Pass) destination.

Controlling Pallets from the Control Panel
The buttons at the bottom of the Control Panel allow you to send commands to control the
movement of pallets on the conveyor. The buttons described below correspond to the
commands that the CIM Manager sends to the PLC device driver.
Before using these buttons, you must first select a station. In order to select a station for the
operations shown below, use the list box of station numbers found along the right-hand edge
of the Control Panel.
Option Description
Deliver Stops the specified pallet when it arrives at the specified station. Select
the desired pallet by clicking on the line with the correct pallet ID. Then
select a station before using this button.
GetFree Stops the next empty pallet that arrives at the specified station. Select the
desired station before using this button.
Free Allows a pallet that was unloaded at this station to continue on the
conveyor and flags it as available (i.e. assigns the pallets destination
station = 99). Select the desired station before using this button.
Release Lowers the piston at the specified station to allow a pallet that is just
passing through this station to continue moving along the conveyor. You
can also use this button to allow a needed pallet to pass if the station is
currently busy. Select the desired station before using this button.
It is NOT recommended to manually select GetFree or Deliver while the CIM is running in
Real Mode. If you do, the CIM Manager will receive an unexpected status message
indicating the arrival of a pallet that did not actually arrive. The CIM Manager will attempt
to recover from this situation by issuing a Free command for this pallet.
Pallet Command Box
You can use the PLC Control Panel as a limited terminal to send commands to a controller.
Commands that you type in the Pallet Command Box are sent out via the PCs serial port
when you press [Enter]. Responses from the PLC are displayed in the Status window of the
device driver.
This capability, which should only be used by PLC programmers, is useful for testing and
debugging PLC control programs.
Simulating a Conveyor
When you want to run a CIM simulation, the PLC device driver can simulate the operation
of pallets moving along the conveyor (when running in Simulation mode or Manual mode).
You can set the following parameters in the appropriate INI file in order to customize the
simulation of the conveyor:
The number of pallets traveling on the conveyor
(SimulationStations)
The number and order of stations around the conveyor
(SimulationPallets)
The distance between stations (SimulationPosPerStation)
The direction in which the conveyor moves
(SimulationDirection)

Hydraulic Device Driver
The hydraulic device driver runs on a PC that controls the hydraulic station via Advantechs
I/O PCI card. This section describes the installation, testing and operation procedures of the
hydraulic device driver and includes the following
Installing the Hydraulic Device Driver
Testing the Hydraulic Device Driver in CIM (Standalone Mode)
Operating the Hydraulic Device Driver in OpenCIM (Real Mode)
(Optional) Operating the Hydraulic Device Driver in OpenCIM
(Offline)
For additional details refer to the following references provided:
Advantech DLL Drivers Users Manual and Programmers Reference.
HYD-2800 Hydraulic Station Maintenance Manual.
Installing the Hydraulic Device Driver

After you have setup the hardware, as described in the HYD-2800 Hydraulic Station
Maintenance Manual, the next step is to install Advantechs DLL driver software. This
includes inserting the PCI-1711 card, installing the device driver and defining the settings.
For additional details refer to the Advantech DLL Drivers Users Manual and Programmers
Reference that was provided with the software.
To install the hydraulic device driver software:
1. From the CD-ROM drive install Advantechs Hydraulic device driver software (that
supports the I/O card installed). From the initial window select the DLL Drivers V1.4
option and proceed to the next step of the installation where you select the required
windows platform, as follows:
2. Select Windows 2000 as your platform.
In Windows Vista/7: When prompted you must enter Administrator credentials or if
you are already administrator click allow.
3. Follow the remaining instructions of the installation wizard to complete the installation
process.
4. Power down the computer.
5. Remove the cover of the computer and insert the PCI-1711 I/O card into one of the
available PCI slots.
6. Replace the cover of the computer.
7. Connect the cable from the rear panel of the hydraulic robot to the computer and power
up the computer.

8. From the windows Start menu, select Advantech Driver v1.4 | Device Installation.
The Advantech IO Device Installation window is displayed.
Figure 9-30: Advantech IO Device Installation

9. From the Device menu, select Setup. The Advantech IO Device Installation window is
displayed.
Figure 9-31: Advantech IO Device Installation

10. From the List of Devices area, select Advantech PCI-1711 and then click Add. The
Advantech PCI-1711 device is displayed in the Installed Devices Area.

11. From the Installed Devices Area select Advantech PCI-1711 and then click Setup. The
PCI-1711 Device Setting window is displayed (in Windows XP).
Figure 9-32: PCI-1711 Device Setting

12. Select both the External options from both the D/A Voltage Ref Channel 1 and D/A
Voltage Ref Channel 2 areas and then click OK. A confirmation message is displayed.
13. Click OK to restart your computer in order for these changes to take effect.
Testing the Hydraulic Device Driver in CIM (Standalone Mode)

After installing the hydraulic device driver, the next step is to test the device driver to verify
that the card is working properly in the CIM environment in standalone mode. This includes
loading the hydraulic device driver from the CIM DDLoader window, and then activating
the Load.pgm, Press.pgm and Unload.pgm applications.
To test the hydraulic device driver in CIM (standalone mode):
1. From the windows desktop double-click the Loader of WS1 icon (where the hydraulic
station is installed). The CIM DDLoader window is displayed.
Figure 9-33: CIM DDLoader (WS1)

2. Select the Load column of the HYDDRIVER then click the
Load Selected Drivers icon to load the Hydraulic Robot Device Driver software.

3. From the windows system tray select Hydraulic Robot Device Driver. The Hydraulic
Robot Device Driver window is displayed.
Figure 9-34: Hydraulic Robot Device Driver

4. From the Control Mode drop down list,.select Standalone. The window is expanded as
follows.
Figure 9-35: Hydraulic Robot Device Driver (Standalone)

5. Click Open. A standard navigation window is displayed.
6. Navigate and select the Load.pgm program and then click Run. The hydraulic robot to
lifts template off the conveyer and places it on the jig.
7. Repeat Step 5, then navigate and select the Press.pgm program and click Run. The
hydraulic robot compresses the template that is placed on the jig.
8. Repeat Step 5, then navigate and select the Unload.pgm program and click Run. The
hydraulic robot removes the compressed template from the jig and places it back on the
conveyer.
This indicates the hydraulic device driver is working properly in the CIM environment.

Operating the Hydraulic Device Driver in OpenCIM (Real Mode)
After installing and testing the hydraulic device driver, you can operate the hydraulic device
driver in the OpenCIM environment in Real Mode. This includes, loading the Hydraulic
Robot Device Driver from the CIM DDLoader window, and running the CIM Manager. The
CIM Manager automatically activates the Load.pgm, Press.pgm and Unload.pgm
applications. This indicates that a connection exists between the hydraulic device driver and
the CIM Manager.
To operate the hydraulic device driver in OpenCIM (realmode):
1. Select the Loader icon of the workstation where the hydraulic device driver is installed.
The CIM DDLoader window is displayed.

2. Ensure that the Simulation column of the HYDDRIVER is deselected and then click
the Load Selected Drivers icon to load the Hydraulic Robot Device Driver
software. The pump is automatically turned on. This indicates the station is working
properly.

3. To review the CIM Messages, select Hydraulic Robot Device Driver from the system
tray. The Hydraulic Robot Device Driver window is displayed, as shown in the
following example:
Figure 9-37: Hydraulic Robot Device Driver
Note To stop the hydraulic robot program execution, do one of the following:
Press F9 hotkey on your keyboard
Click the Abort button from the Hydraulic Device Driver window.
Click the Emergency Stop button on the front panel of the hydraulic station.
You can then click Continue from Hydraulic Device Driver window to
proceed.(If the Emergency Stop button was pressed, you must first release it
before clicking Continue to proceed.)
(Optional) Operating the Hydraulic Device Driver in OpenCIM

(Offline)
The Hydraulic Robot Device Driver window enables you to operate the hydraulic device
driver offline and create your own programs according to your needs.
For additional details refer to the Advantech DLL Drivers Users Manual and Programmers
Reference that was provided with the software.
To operate the hydraulic device driver in OpenCIM (offline):
1. Select the Loader icon of the workstation where the hydraulic device driver is installed.
The CIM DDLoader window is displayed, as shown in Figure 9-36: CIM DDLoader.
2. Ensure that the Simulation column of the HYDDRIVER is deselected and then click
the Load Selected Drivers icon to load the hydraulic device driver software. The
pump is automatically turned on. This indicates the station is working properly.
3. From the windows system tray select Hydraulic Robot Device Driver. The Hydraulic
Robot Device Driver window is displayed, as shown in Figure 9-37: Hydraulic Robot
Device Driver.
4. From the Control Mode drop down list, select Standalone. The window is expanded as
shown in Figure 9-35: Hydraulic Robot Device Driver (Standalone).

5. Select Go Offline. The Hyd-2800 window is displayed.
Figure 9-38: HYD-2800 (Offline)

6. You can now create your own programs according to your requirements.
Click CIM-Online to return to the Hydraulic Robot Device Driver window at any time
7. After creating your program you can define it in the OpenCIM Manager application, as
follows:
Launch the OpenCIM Manager application.
Select Utility Programs | Machine Definition. The CIM Machine Definition window is
displayed, see Machine and Process Definitions in Chapter 5, for further details.
Define the process to be performed by the hydraulic robot and enter the program name in the
Program column.

Pneumatic Device Driver
The pneumatic device driver runs on a PC that controls the pneumatic station via the Vuniq
software. This section describes the installation, configuration, operation and troubleshooting
procedures of the pneumatic device driver and includes the following:
Installing the Vuniq Software
Configuring the Vuniq Application Settings
Operating the Pneumatic Device Driver in OpenCIM - Real Mode
Pneumatic Station Troubleshooting
PN-2800 Pnuematics Application Operators Manual, Instructor's
Manual
PN-2800 Pnuematics System Student Manual

After setting up the hardware station, as described in the Pneumatics Application Operators
Manual, the next step is to install the Vuniq software that supports the pneumatic station
hardware. This includes inserting the licence plug, copying the application files to the default
directory and more.
To install the Vuniq software:
1. From the CD-ROM drive install the Vuniq for Windows application 4.5 and follow the
instructions provided in the installation wizard. When the installation is complete, the
Vuniq icon is displayed on your desktop.

2. Install the license plug in the parallel port on the PC.
3. Copy the \\Projects\LIB\Vuniq40 directory from manager computer on local network
to the [default system drive (for example C:)]\vuniq40 directory on the workstation
computer. This directory contains the files that are required to configure the Vuniq
Application Manager to work with the pneumatic station.
Note These directories containing the files required to configure the Vuniq Application
Manager are the default directories and can be changed as required.
4. From the Start menu select Vuniq or double-click the Vuniq icon from your
windows desktop. In Windows Vista/7 you should right-click the icon and select Run
as Administrator. The Vuniq for Windows main window is displayed and the Vuniq
icon appears on your system tray.
5. From the Windows system tray, right click the Vuniq icon. A popup menu is
displayed.

6. Select Application Manager. The Vuniq Application Manager window is displayed.
Figure 9-39: Vuniq Application Manager (Pneumatics)

7. In the Current application path field, enter the C:\Vuniq40\pn2000 path that was
defined as the default directory during the installation process.
8. Click Restart. Pneumatics Station window (shown in Figure 9-41: Pneumatics Station)
is displayed in the background. Click Close to close the Vuniq Application Manager
window.

After installing the Vuniq software, the next step is to define the Vuniq application settings.
This includes defining the port number and verifying that communication exists between the
pneumatics station and the computer.
To define the Vuniq Application Settings:
1. From the Windows system tray, right-click the Vuniq icon. A popup menu is
displayed.
2. Select Application Settings. The Vuniq Applications Settings window is displayed.
3. From the Category area, select Communications, the General tab appears in the
Communications area.
Figure 9-40: Vuniq Applications Settings

4. From the Port drop down list select the required port number. (The default port number
is COM1) and click OK.
5. Right-click the Vuniq icon. A popup menu is displayed.

6. Select Operator Screens. The Pneumatics Station window is displayed.
Figure 9-41: Pneumatics Station
7. Verify that the button is green to indicate that the communication between the
pneumatics station and the computer is working properly.
Note If the
button is not displayed in green press or press the PLC ON
button on the front panel of the pneumatics station.
8. Right-click the Vuniq icon. From the displayed popup window select Quit and
then click Yes at the displayed confirmation message to exit the Vuniq application.

Operating the Pneumatic Device Driver in OpenCIM - Real Mode
After installing the software and defining the settings, you can operate the pneumatic device
driver in the OpenCIM environment in real mode. This includes, loading the Pneumatic
Robot Device Driver from the CIM DDLoader window, and running the CIM Manager.
To operate the pneumatic device driver in OpenCIM (realmode):
1. Select the Loader icon where the pneumatic station is installed. The CIM DDLoader
Figure 9-42: CIM DDLoader (PNEUDRIVER)

2. Ensure that the Simulation column of the PNEUDRIVER is deselected and then click
the Load Selected Drivers icon to load the Pneumatic Station Device Driver
software. This activates the pneumatic device driver and displays the Pneumatics
Station window. Verify that the and buttons are displayed in green,
to indicate that the station is working properly in the OpenCIM environment.
3. To review the CIM Messages, select Pneumatic Station Device Driver from the
system tray. The Pneumatic Station Device Driver window is displayed, as shown in the
following example:
Figure 9-43: Pneumatic Station Device Driver
Note To stop the pneumatic robot program execution, press the Emergency Stop button
on the front panel of the pneumatic station.

Pneumatic Station Troubleshooting
Whenever a problem is detected with the operation of the pneumatic station device driver in
the OpenCIM environment, the pneumatic station Error led is automatically turned on and
the Pneumatic Station Device Driver window appears (as shown in Figure 9-44: Pneumatic
Station Device Driver Error Message). This section describes how to correct the example
error messages that may appear.
Station Not Ready - Error Message
This message can appear due to the following reasons:
The Emergency button is pressed on the pneumatic station
Solution: Release the Emergency button and then press the and buttons.
The pneumatic station is working in Standalone Mode or Basic Operations mode.
Solution: Deselect the button or button and then click the button
in the Pneumatics Station window.
The PLC ON button on the pneumatic station is turned off.
Solution: Press The PLC ON button or click the button and then click the
button in the Pneumatics Station window.
Block is Missing Error Message
This message appears when a block is missing. To correct the error follow the procedure
described below.
An example of an error message is displayed below.
Figure 9-44: Pneumatic Station Device Driver Error Message

To reset the error and continue with the pneumatic process:
1. From the Pneumatics Station Device Driver window select the button to reset
the error status on the pneumatic station. The pneumatic station's Error led is turned off.
2. Manually Place the block on the template or in the feeder as required.

Select this option after manually placing the block on the template.
Select this option after manually placing the block in the feeder to enable the
pneumatic station to proceed with the process.
The pneumatic station will proceed with the process.

Process Device Driver
The process device driver runs on a PC that controls the process station via the Vuniq
software. The station is controlled via PLC, using an RS232 interface. This section describes
the installation, configuration, operation and troubleshooting procedures of the process
device driver and includes the following:
Operating the Process Device Driver in OpenCIM - Real Mode
Viewing the Processing Station Information
Process Station Troubleshooting
PS-2800 Process Control Maintenance Manual
PS-2800 Coating System Student Manual
The process station consists of seven baths. Each bath has a specific function. The station
performs the following tasks in the OpenCIM environment:
Lifts the template and raw material off the conveyer and places it on the buffer.
Lifts the raw material off the template and performs the process that is displayed in the
Vuniq software. At the end of this process the processed part is placed back on the
template.
Lifts the template and processed part off the buffer and places it back on the conveyer.

After setting up the hardware station, as described in the PS-2800 Process Control
Maintenance Manual, the next step is to install the Vuniq software that supports the process
station hardware. This includes inserting the licence plug, copying the application files to the
default directory and more.
To install the Vuniq software:
1. From the CD-ROM drive install the Vuniq for Windows 4.5 application and follow the
instructions provided in the installation wizard. When the installation is complete, the
Vuniq icon is displayed on your desktop.

2. Install the license plug in the parallel port on the PC.
3. Copy the \\Projects\LIB\Vuniq40\proc directory from manager computer on local
network to the [default system drive (for example C:)]\vuniq40 directory on the
workstation computer. This directory contains the files that are required to configure
the Vuniq Application Manager to work with the process station.

Note These directories containing the files required to configure the Vuniq Application
Manager are the default directories and can be changed as required.
4. From the Start menu select Vuniq or double-click the Vuniq icon from your
windows desktop. In Windows Vista/7, right-click the icon and select Run as
Administrator. The Vuniq for Windows main window is displayed and the Vuniq
icon appears on your system tray.
5. From the Windows system tray, right click the Vuniq icon. A popup menu is
displayed.
6. Select Application Manager. The Vuniq Application Manager window is displayed.
Figure 9-45: Vuniq Application Manager (Process)

7. In the Current application path field, enter the [default system drive (for example
C:)]\Vuniq40\proc path that was defined as the default directory during the installation
process.
8. Click Restart. The Main Process Station window (shown in Figure 9-47: Main Process
Station) is displayed in the background. Click Close to close the Vuniq Application
Manager window.

After installing the Vunig software, the next step is to define the Vuniq application settings.
This includes defining the port number and verifying that communication exists between the
pneumatics station and the computer.
To define the Vuniq Application Settings:
1. From the Windows system tray, right-click the Vuniq icon. A popup menu is
displayed.
2. Select Applications Settings. The Vuniq Application Settings window is displayed.
3. From the Category area, select Communications, the General tab appears in the
Communications area.
Figure 9-46: Vuniq Applications Settings (Process)

4. From the Port drop down list select the required port number. (The default port number
is COM1) and click OK.

6. Select Operator Screens. The Main Process Station window is displayed.
Figure 9-47: Main Process Station
process station and the computer is working properly.
Note
If the button is not displayed in green press or press the PLC ON
button on the front panel of the process station.
8. Right-click the Vuniq icon. From the displayed popup window select Quit and
then click Yes at the displayed confirmation message to exit the Vuniq application.

Operating the Process Device Driver in OpenCIM - Real Mode
After installing the software and defining the settings, you can operate the process device
driver in the OpenCIM environment in Real Mode. This includes, loading the Process
Station Device Driver from the CIM DDLoader window, and running the CIM Manager.
To operate the process device driver in OpenCIM (realmode):
1. Select the Loader icon where the process station is installed. The CIM DDLoader
Figure 9-48: CIM DDLoader (process)

2. Ensure that the Simulation column of the PROCDRIVER is deselected and then click
the Load Selected Drivers icon to load the Process Station Device Driver software.
This activates the process device driver and displays the Main Process Station window.
Verify that the and buttons are displayed in green, to indicate that
the station is working properly in the OpenCIM environment.

3. To review the CIM Messages, select Process Station Device Driver. The Process
Station Device Driver window is displayed, as shown in the following example:
Figure 9-49: Process Station Device Driver

Note To stop the process robot program execution, press the Emergency Stop button on the front
panel of the process station.

Viewing the Processing Station Information
You can view the processing stages at any time throughout the process from the Process
Station - Program Screen window. Information includes, cycle, time set, bath number and
more.
To view the processing stages:

2. Select Operator Screens. The Process Station - Program Screen window is displayed.
Figure 9-50: Process Station Program Screen
process station and the computer is working properly.
Note If the
button is not displayed in green press or press the PLC ON
button on the front panel of the process station.
You can now view the various stages of the process, such as the amount of time that a
specific part remains in a specific bath and so on.

Process Station Troubleshooting
Whenever a problem is detected with the operation of the process station device driver in the
OpenCIM environment, the process station Error led is automatically turned on and an Error
Screen appears in the CIM Manager application (as shown in the example below).
Figure 9-51: CIM Manager Error Screen

To correct process station errors:
1. From the CIM Manager Error Screen, click . The Process Station Device
Driver window appears displaying the error that occurred in the system.
Figure 9-52: Process Station Device Driver - Error Message

3. Select Operator Screens. The Main Process Station window is displayed, as shown in,
Figure 9-47: Main Process Station.

4. From the Main Process Station window, deselect the button and then select the
button to enter basic operations mode.
5. From the General area, select the button that is located to the right of the
Manipulator Control option. The Process Station - Manipulator Control Screen is
displayed.
Figure 9-53: Process Station - Manipulator Control Screen
6. From the Gripper area, select the arrow button that is located to the right of the
option. The robot is sent to the home position.
7. Deselect the button and then select the button to enter Real Mode.
8. Click the icon to return to the Main Process Station window (shown in Figure
9-47: Main Process Station).
9. From the CIM Manager main window, select the red Stop icon to stop the
processes in the OpenCIM environment.
10. Correct the problem manually and then press the green Start icon to restart the
process.

10
Web Viewer
The Web Viewer application enables you to remotely access a specific CIM Manager cell
and track the production cycle of the CIM cell from the various view tabs. This includes, the
graphic display of the operations being performed, the actions performed on system devices
as they occur in the production cycle, information regarding the storage locations and more.
This chapter describes how to install and access the Web Viewer client. It includes the
following:
Installing the Client, describes how to install the web viewer client
application.
Accessing the Web Viewer, describes how to activate the web
viewer application.
Web Viewer Main Window, introduces the elements of the web
viewer main window.
Before accessing the Web Viewer, you must first verify that the IIS is installed and that the
the DCOM has been configured (described in Chapter 4, Installation). You must then
Note
verify that the Web Viewer mode is activated (described in CIM Modes, Chapter 6,
Operating CIM Manager).

Web Viewer
Installing the Client
The Web Viewer client is installed through Internet Explorer (version 5.0 and higher). If
required you can save the installation file to a specified directory for future installations.
To install the Web Viewer client:
1. From your Start menu, click the Internet Explorer icon. The Internet Explorer
main window is displayed.
2. In the Address field enter the IP or hostname of the computer containing the
CIM Manager that you want to install from, as in the following examples:
http://<hostname>/webcimviewer/start.asp
OR
http://<IP Address>/ webcimviewer/start.asp
The OpenCIM Web Viewer Initial page is displayed.
Figure 10-1: Web Viewer Installation Window

3. Click Download the File Download window is displayed.
Figure 10-2: Web Viewer Download Window

Web Viewer
Select Run in order to run this program from its current location.
The Web Viewer Client Setup window is displayed. When the installation is
complete, click Finish.
OR
Select Save in order to save this program to a specified directory for future
installations.
After you have installed the client the next step is to access Web Viewer, as described in
Accessing the Web Viewer.

Web Viewer
Accessing the Web Viewer
Before accessing the Web Viewer, ensure that the CIM Manager that you want to access is
currently open.
To access the Web Viewer:
1. From your Start menu, click the Internet Explorer icon. The Internet Explorer
main window is displayed.
2. In the Address field enter the IP or hostname of the computer containing the CIM
Manager that you want to access according to the following examples:
http://<hostname>/webcimviewer/start.asp
OR
http://<IP Address>/webcimviewer/start.asp
The OpenCIM Web Viewer Initial window is displayed, as shown in Installing the Client.
3. Click Start. The Open CIM Web Viewer appears displaying the Graphic Display tab,
as shown in Graphic Display Tab.
If the CIM Manager of the computer that you want to access is currently inactive, an
information dialog box is displayed, informing you that CIM Manager that you
Note
currently want to access is currently closed.

Web Viewer
Web Viewer Main Window
The Web Viewer main window contains the following elements, each of which is described
in the sections that follow:
Graphic Display Tab, displays a 3D display of the operation being
performed in the CIM cell.
View Scheduler Tab, displays the scheduler information of the CIM
cell.
View Program Tab, displays the A-Plan (meaning, the production
work order) of the CIM cell.
View Leaf Tab, displays the production activities in the CIM cell.
View Order Tab, displays the current manufacturing order.
View Storage Tab, displays the current location of parts in the CIM
cell.
View Device Tab, displays the actions performed by system devices.
View Pallet Tab, displays the pallets in the CIM cell the current
status of each pallet.
Web Viewer Status Bar, displays CIM cell information, such as
current status, elapsed time and more.
View About Tab, displays dialog with information about Web CIM
Viewer software and CIM software of the Cell that is current in view.
Graphic Display Tab
Figure 10-3: Graphic Display Tab

Web Viewer
The Graphic Display tab enables you to view the graphic display that currently appears on the
CIM Manager of the computer that you are currently accessing. For further information refer
to Graphic Display and Tracking in Chapter 6, Operating CIM Manager.
View Scheduler Tab
Figure 10-4: View Scheduler Tab

The View Scheduler tab enables you to view the current (planned and actual) scheduler
information of the CIM Manager that you are accessing. For further information refer to
CIM Scheduler in Chapter 6, Operating CIM Manager.
View Program Tab
Figure 10-5: View Program Tab

Web Viewer
The View Program tab enables you to view the current production work order of the CIM
Manager that you are currently accessing. This enables you to track the current production
status of the CIM Manager. For further information refer to Program View in Chapter 6,
Operating CIM Manager.
View Leaf Tab
Figure 10-6: View Leaf Tab

The View Leaf tab enables you to view the description of the current production activities in
the current CIM cell of the CIM Manager that you are accessing, describing the current
operation being performed on each item as well as the operation that will follow
immediately. For further information refer to Leaf View in Chapter 6, Operating CIM
Manager.
View Order Tab
Figure 10-7: View Order Tab

The View Order tab enables you to view a copy of the manufacturing order of the current
cell of the CIM Manager that you are accessing. For further information, refer to Order View
in, Chapter 6, Operating CIM Manager.

Web Viewer
View Storage Tab
Figure 10-8: View Storage Tab

The View Storage tab enables you to view a list of every storage location defined in the CIM
system. For further information, refer to Storage View in Chapter 6, Operating CIM
Manager.

Web Viewer
View Device Tab
Figure 10-9: View Device Tab

The View Device tab enables you to view a list of every robot and machine (including QC
devices) as well as a description of the current action being performed in the current CIM
Cell of the CIM Manager that you are accessing. For further information, refer to Device
View in Chapter 6, Operating CIM Manager.
View Pallet Tab
Figure 10-10: View Pallet Tab

The View Pallet tab enables you to view a list of every pallet in the CIM Cell and a
description of its current status. For further information, refer to Pallet View in Chapter 6,
Operating CIM Manager.

Web Viewer
Web Viewer Status Bar
The Web Viewer status bar consists of the following elements:

Option Description
Status: Displays information regarding the status of the CIM Manager that
you are accessing, as follows:
Manager is Open: Displayed as soon as the CIM Manager
is opened.
Manager is Closed: Displayed when the CIM Manager is
closed.
Synchronizing Graphics: Displayed when synchronizing
graphics of the current state of the CIM Manager that you
are acccesing.
Current State: Displayed when the current graphic state of
the CIM Manager is displayed in the Graphic Display tab.
Time: The time that has passed since the start of production in the CIM
Manager.
Mode: CIM Manager modes of operation:

Simulation Mode: The CIM Manager does not
communicate with device drivers. This mode does not
require either hardware or device drivers in order to
operate.
Real Mode: The CIM Manager commmunicates with all
device drivers, whether or not hardware is in use. This
mode requires that all device drivers which are need for a
specfic application be loaded, so that the CIM Manager can
transmit and receive messages.
Graphic Messages: Graphic messages that appear describing the graphic process.
The Order is Completed message appears at the end of the
production process, indicating the order has been complete.

Web Viewer
View About Tab
The Web Viewer About tab displays a dialog with information about CIM software and Web
CIM Viewer software, and a shortcut to the Intelitek web site for support and information.
Figure 10-11: View About Tab

Web Viewer
11
OpenCIM Programming
This chapter provides various programming and advanced OpenCIM features. It includes the
following sections:
Robotic Programming for OpenCIM, describes the robotic
programming commands in OpenCIM.
CNC Programming for OpenCIM, describes the CNC
programming commands in OpenCIM.
Robot and CNC Interface, describes the CNC synchronization
mechanism in OpenCIM.
Optimization Enhancement Using Open Source, describes how to
add new algorithms to the existing list of algorithms in the CIM
Optimization Manager.
Experimenting with Production Strategies Using the A-Plan,
describes the structure of the A-Plan and provides instructions how to
modify it.

OpenCIM Programming
Robotic Programming for OpenCIM
In the course of production, OpenCIM uses a set of robotic programs which control the
movement of robots and the operation of peripheral devices connected to a robotic
controller. When you want to teach a robot (or other device) to perform a new task or to
achieve better performance at a task, you need to edit or create robotic programs. This need
arises when you:
Install a new device at a station.
Move a device or a robot to a new location.
Add or change a process or part definition (in the Machine Definition
or Part Definition utility programs) that relies on a robotic program.
Add or change robot tasks or parameters. For example: speed (slow,
medium, fast) or the way the robot moves (linear, circular, etc.).
Add or change the parameters of the devices attached to the robotic
controller.
This section describes how to write robotic programs in the OpenCIM environment. These
programs direct a robot (or other device attached to a robotic controller) to:
Move an object from place to place (pick-and-place operation).
Perform certain system functions (e.g. how to react in case of a robot
collision).
Perform some other production process (e.g. bar code, pneumatic
screwdriver, CNC interface, etc.)
The Pick-and-Place Strategy

OpenCIM uses the pick-and-place strategy to minimize the number of custom robotic
programs required to transfer parts between locations at a station.
Having fewer programs yields several benefits:
Less programming effort to write the original programs.
Fewer changes to be made in the event devices are added, deleted, or
moved.
Fewer problems and easier to debug since all GET and PUT
programs share a common structure.
Requires less memory in the robotic controller
Instead of writing individual robotic programs to move a part between two locations (a
point-to-point approach), the pick-and-place strategy provides a more systematic method that
requires only two programs for each location, a GET and PUT. A GET program picks up a
part from a location. A PUT program places a part at a specific location. GET and PUT
programs for different locations are designed to work together to allow the robot to take a
part from any location (GET) and deliver it to any other location (PUT).
For example, if there are six locations at a station, it would require 30 point-to-point
programs to cover all the possible combinations of moving a part between any two locations.
The pick-and-place approach requires only 12 programs (6 GETs and 6 PUTs).
A Free Movement Zone is the key to getting GET and PUT programs to work together. This
zone is a region approximately meter above work surface in which the robot can move
freely and quickly between locations without encountering any obstacles.

OpenCIM Programming
The first operation in a GET or PUT program is to move the robot in a straight line to a
position directly above the location where it is needed. From there, a program uses a set of
detailed robotic commands to maneuver the robot arm to a point where it can pick up or
place a part at a specific location. When a GET or PUT begins executing, it assumes that the
robot arm is in the Free Movement Zone waiting for a command.
A typical pick-and-place scenario is shown in the figure below. In this scenario, the CIM
Manager sends a command to move a part from buffer 2 to a ROBOTVISIONpro camera for
a quality control test. This pick-and-place command is sent to the robotic device driver. The
device driver in turn sends commands to the robotic controller to run the corresponding GET
and PUT programs described below.
Figure 11-1: Robot Movements Controlled by Separate GET and PUT Programs
GET (from buffer 2)
1. Move the empty robot arm in a straight line through the Free Movement Zone to a point
directly above the buffer.
2. Lower the arm and grab the part from the template sitting in the buffer.
3. Raise the arm back up to the Free Movement Zone directly above the buffer.
PUT (under the camera)
1. Move the robot arm holding the part through the Free Movement Zone to a point above
the ROBOTVISIONpro camera's viewing area.
2. Lower the arm and set the part within the camera's field of view.
3. Raise the arm back up to the Free Movement Zone directly above the camera.
At end of the GET, the robot is holding the part in the Free Movement Zone while it waits
for the PUT program to begin executing.
At the end of the PUT, the robot is empty and it waits in the Free Movement Zone for the
next GET operation.

OpenCIM Programming
Overview of a Pick-and-Place Command
The CIM Manager tells a robot to move a part/template from one device at a station to
another by sending a pick-and-place command to the appropriate robotic device driver. The
device driver tells the controller to run the robotic programs GET and PUT that are
associated with the locations specified in the pick-and-place message.
Each device has a GET program associated with it which tells a robot how to move in order
to pick up a part at this location. Similarly, each device has a PUT program which tells a
robot how to place a part at this location. The names of these robotic programs take the form
of GTxxx and PTxxx (for ACL programs) and GETxxx and PUTxxx (for Scorbase
programs), where xxx is the ID of the device.
The device driver tells the controller to run the appropriate GTxxx and PTxxx that are
associated with the locations specified in a pick-and-place command.
Each GET program is dedicated to picking up an object from a single location. Each PUT
program is dedicated to delivering an object to a single location.
In order to move a part from any location at a station to any other location, all GET and PUT
programs are designed to be used together in any combination.
For example, to move a template from the ASRS to a pallet waiting on the conveyor, a
pick-and-place command would specify running the following robotic programs:
GT002 - Take template from ASRS (002 = ASRS device ID).
PT001 - Put template on conveyor pallet (001 = device ID for
conveyor)
Note that the device IDs for GET and PUT are different. If they were the same this would
mean that the robot was returning the part/template to the same location where it had just
picked it up.
All GET and PUT programs for a robot must be designed to work together. This entails that:
They read the same set of pick-and-place parameters (stored in global
variables).
When a program ends, it must leave the robot in a position that
enables it to move in any subsequent direction (since you do not
know at the time of writing the programs where the next GET or
PUT will send the robot).
They use the same synchronization mechanism which allows a GET
program to activate any PUT program.
The names of the Robotic programs are different for ACL programs and Scorbase programs, as
follows:
Note
GTXXX and PTXXX are used for ACL programs.
GETXXX and PUTXXX are used for the Scorbose programs.

OpenCIM Programming
Teaching Robot Positions
The path that a robot follows is made up of points called robot positions. These positions can
be taught using a teach pendant or robotic software, for example, ACL or Scorbase. The
coordinates associated with these positions are normally stored in the required program file
See the robotic documentation for a complete discussion of how to teach robot positions.
When planning robot movements, take into consideration obstacles caused by parts under
production. For example, after placing a part, the robot may not be able to retrace its
Tip
movements without colliding with the part it just placed.
Also note that the same part at the same location may require two different robot positions
before and after an assembly operation.
Response Messages (from Robotic Programs to the CIM Manager)

The programs GET and PUT send the Start, Finish and End status messages to the CIM
Manager via the robotic device driver, each of these messages is described in the table
below.
Status Message Description
Start The GET program sends a Start message to report that the robot has grasped the
part/template and has moved clear of the source device. This Start message
indicates that the source device can continue with other processing even while the
robot continues to move.
The Start message can speed up time critical operations in the CIM. For example,
strategic placement of the Start message can be used to expedite the flow of pallets
on the conveyor. As soon as a robot has lifted a template from a pallet, the GET
program sends a Start message. The CIM Manager can then release the pallet even
while the robot continues to move the template.
Finish The PUT program sends a Finish message to report that the robot has placed the
part/template at the destination device. The Finish message indicates that the
destination device can now proceed to process the part/template even while the
robot continues to move back to its idle position.
The Finish message can be used to speed up time-critical operations in a manner
similar to the Start message. For example, as soon as a robot has placed a template
on a conveyor pallet and moved out of the way, the PUT program can send a Finish
message. The CIM Manager can then release the pallet even while the robot
continues to move to its final resting position.
End The PUT program sends an End message to report that the robot has completed this
pick-and-place operation and is now available for the next command.
In order to avoid delaying the conveyor unnecessarily, send the Start and Finish messages as
soon as possible when writing GET and PUT programs that deal with moving a part template
Tip
to/from a conveyor pallet.
For most other devices, the Finish and End messages typically come one right after the other
at the end of the PUT program.
Sending Response Messages from ACL Programs to the CIM Manager

The code that actually sends the response messages from the ACL program is contained in
the macros .START, .END, .FINISH. These are found in the PROGRAM_GET XXX and
PROGRAM_PUT XXX example programs.
To send response messages from ACL Programs to the CIM Manager:

OpenCIM Programming
Insert the following macros in the appropriate places in your own
GET and PUT programs:
Start: The Start message is sent by the macro .START.
Finish: The Finish message is sent by the macro .FINISH.
End: The End message is sent by the macro .END.
The macros for all three messages, Start, Finish, and End, take care of returning the
command sequence number stored in the parameter variable $ID. This value allows the CIM
Manager to identify the source of the message.
Sending Response Messages from the Scorbase Software to the CIM Manager/Device
Driver
The Send Message window is used for creating the Send Message command in the Scorbase
program. When the program is activated and begins to run, the Send Message command is
then forwarded to the CIM Manager or device driver, as described in the following
procedures:
To send response messages from Scorbase to the CIM Manager:
1. From the Scorbase main window, select Window | Teach & Edit. Select Options | Pro
from the Menu bar. From the Workspace window expand the Program Flow tree and
double click SendMessage. The Send Message window is displayed:
Figure 11-2: Send Message Window CIM Manager Option Selected

2. From the Send To dropdown list select the MANAGER option.
In the Send To dropdown list the Manager option is displayed by default. In the Task ID field
the TASK_ID option is displayed by default.
Note
3. From the Type dropdown list select the required response message as follows:
$Start
$Finish
$End
4. Click OK. The response message is displayed in the program window.
This procedure is applicable only when the Scorbase device driver is in online mode.
Note
To send response messages from Scorbase to the Device Driver:

OpenCIM Programming
1. From the Scorbase main window, select Window | Teach & Edit. Select Options | Pro
from the Menu bar. From the Workspace window expand the Program Flow tree and
double click SendMessage. The Send Message window is displayed.
Figure 11-3: Send Message Window Device Driver Option Selected

2. From the Send To dropdown list select the Device Driver option.
3. In the Device ID field enter the ID of the device.
4. In the String field enter the string that the Device Driver is waiting to receive.
5. Click OK. The response message is displayed in the program window.
This procedure is applicable only when the Scorbase device driver is in online mode.
Note
Viewing the Response Messages in CIM Manager

You can monitor the progress of robotic programs at run-time by looking at the Program,
Leaf or Device Views in the CIM Manager program. When a robot is performing a
pick-and-place command, the following messages let you follow the progress of the GET
and PUT programs as they execute.
Run-Time Message
Description
ON The Start macro in the GET program has executed.
OFF The Finish macro in the PUT program has executed.
Blue The End macro in the PUT program has executed.
Box
Pick-and-Place Parameters
The CIM Manager sends a set of parameters to a robotic device driver whenever it issues a
pick-and-place command. The device driver in turn activates the PCPLC program in the
robotic controller which receives these parameters and assigns them to the following global
variables:

OpenCIM Programming
Robotic Pick & Place Parameters Description
Scorbase ACL
TASK_ID $ID A sequence number generated by the CIM Manager for
each command (a pick-and-place command in this case).
Whenever a robotic program sends a status message, it
includes this command ID so that the status message can
be associated back to the original command.
PART_ID PART The ID number of the part that the robot is to handle.
This number corresponds to the Part ID field in the Part
Definition form. For each part type, the instructions for
how the robot grasps the part is defined in the robotic
program (ACL or Scorbase). For example, the positions
for each part ID is stored in an array (such as, CIM[ ]).
The part ID can be used to calculate an index into this
array.
A template is identified with a Part ID of zero.
SOURCE_DEVICE_ID $DEV1 The device ID of the source location where the robot will
pick up the part/template.
SOURCE_DEVICE_INDEX INDXG For a source device that has multiple compartments
(e.g. a storage rack), this parameter specifies in which
compartment (or buffer) the robot will find the
part/template.
TARGET_DEVICE_ID $DEV2 The device ID of the target location where the robot will
place the part/template.
TARGET_DEVICE_INDEX INDXP For a target device that has multiple compartments
(e.g. a storage rack), this parameter specifies in which
compartment (or buffer) the robot should place the
part/template.
PICK_AND_PLACE_NOTE $NOTE This parameter is available for user-defined purposes to
send special instructions to a GET or PUT program. For
example, when the part to be handled is a template (with
ID=0), the note parameter will indicate the part ID of the
part on the template. This enables the Scorbase
programmer to include special instructions for specific
parts, such as, slower movements for sensitive parts and
more.

OpenCIM Programming
Writing Scorbase Source Code
The Scorbase program consists of two parts. The first part (lines 1 through 14) is created
automatically when you select the parameters from the Pick and Place window, the second
part (from line 15 to the end) contains GET XX and PUT XX programs for each device in
the CIM system. These GET XX and PUT XX programs are written by the programmer.
An example of a Scorbase program is displayed, as follows:
Remark: $ Beginning of the automatically generated code
Call Subroutine $PICK_AND_PLACE_0,1,3,15,2,0
Set Subroutine $PICK_AND_PLACE_0,1,3,15,2,0
Set Variable TASK_ID = 110000
Set Variable PART_ID = 0
Set Variable SOURCE_DEVICE_ID = 1
Set Variable SOURCE_DEVICE_INDEX = 3
Set Variable TARGET_DEVICE_ID = 15
Set Variable TARGET_DEVICE_INDEX = 2
Set Variable PICK_AND_PLACE_NOTE = 0
Call Subroutine AUTOEXEC
Call Subroutine GET001
Call Subroutine PUT015
Return from Subroutine
Remark: $ End of the automatically generated code
Remark: Intelitek Open CIM robot device driver demonstration
Remark: The ER-4u robot serves the Conveyor (CNV1)
Remark: The ER-4u robot serves the MINI-ASRS (M6AS2)
Set Subroutine GET015
Print to Screen: GET TEMPLATE FROM MINI-ASRS (M6AS2)
Go to Position 21 Speed 5
Open Gripper
Set Variable ABOVE_TEMPLATE_POSITION = SOURCE_DEVICE_INDEX +
110
Go to Position ABOVE_TEMPLATE_POSITION Speed 8
Set Variable AT_TEMPLATE_POSITION = ABOVE_TEMPLATE_POSITION -
100
Go Linear to Position AT_TEMPLATE_POSITION Speed 2
Close Gripper
Go Linear to Position ABOVE_TEMPLATE_POSITION Speed 2
Go Linear to Position 2 Speed 2
Open Gripper
Send Message $Start to MANAGER for task TASK_ID
Set Subroutine PUT015
Print to Screen: PUT TEMPLATE ON MINI-ASRS (M6AS2)

OpenCIM Programming
Open Gripper
Close Gripper
Set Variable ABOVE_TEMPLATE_POSITION = SOURCE_DEVICE_INDEX +
110
Go to Position ABOVE_TEMPLATE_POSITION Speed 8
Set Variable AT_TEMPLATE_POSITION = ABOVE_TEMPLATE_POSITION -
100
Open Gripper
Send Message $Finish to MANAGER for task TASK_ID
Go to Position 20 Fast
Send Message $End to MANAGER for task TASK_ID
Set Subroutine GET001
Print to Screen: GET TEMPLATE FROM CONVEYOR (CNV1)
Open Gripper
Go to Position 10 Fast
Close Gripper
Open Gripper
Send Message $Start to MANAGER for task TASK_ID
Print to Screen: PUT TEMPLATE ON CONVEYOR (CNV1)
Open Gripper
Send Message $Finish to MANAGER for task TASK_ID
Send Message $End to MANAGER for task TASK_ID
If the programmer defined an AUTOEXEC subroutine in the program, then the
Call AUTOEXEC SUBROUTINE will appear in the automatically generated
Note
section of the program (lines 1 through 14).

OpenCIM Programming
Writing ACL Source Code
The Robot programs are comprised of all the associated programs necessary to run the robot.
The Robot programs are divided into individual programs as follows:
Get and Put programs of each device.
Quality Control programs of each peripheral QC device (e.g. Bar
code).
Process (PRL programs) programs of each peripheral machine (e.g.
automatic screwdriver, CNC machine)
Structure of the ACL Program
File Description
CIMSYS.DMC Located in the Projects\LIB\ACL LIB/ACL directory. This file
contains system macros.
CIMSYS.SYS Located in the Projects\LIB\ACL LIB/ACL directory. This file
contains system programs.
All of the following files are located at the current directory of Robotn:
File Description
WSn.DNL Includes all of the files that are to be downloaded from your station PC
to the ACL controller.
PROLOGn.DNL In this file you modify system programs, such as Global System
variables (e.g. SPSA - speed slow group A), predefined positions or
any other settings that need to be predefined for that station. This file
contains all the documentation for positions and I/O.
GET/PUT.DNL Pick-and-place programs.
QC.QCL Quality Control programs.
PROCESS.PRL Process programs.
EPILOGn.DNL In this file you modify Initialization System programs.
You can manage all of your Robot programs through the Robot Programs window. Any
editing changes, however small, should be made to the original DNL, QCL or PCL files.
Device Definition
The Setup directory contains a file which defines numbers to their ACL logical name. This
file includes all the devices in the system. For example:
#IFNDEF _DEVICE_DMC
#DEFINE _DEVICE_DMC
#DEFINE CNV1 001
#DEFINE ASRS 003
#DEFINE ASMBUF 004
#DEFINE BFFR1 005
#DEFINE FDR1 006
#DEFINE TRASH1 007
#DEFINE RACK1 008
#DEFINE RDR1 009
#DEFINE LATHE1 010
#DEFINE MILL1 011
#ENDIF

OpenCIM Programming
ACL Macro Programs
The Projects\LIB\ACL directory contains the file CIMSYS.DMC. This file includes the
system programs and macros which you will use in writing your own ACL programs:
Part ID Group (PID)
Robot Movements
Synchronization
Open/ Close Gripper
Speed
GET/ PUT Programs
QC Programs
Process Programs

OpenCIM Programming
The following listing is the source code of CIMSYS.DMC. This file contains system
programs, macros, and global variable definitions that are needed when writing your own
ACL programs.
;
; OpenCIM-ACL Program
;
; This Is The Cim Macro File
; For All Stations
;Global definitions
#IFNDEF _CIMSYS_DMC
#DEFINE _CIMSYS_DMC
#DEFINE _CIMSYSM_DMC
;Part macro
#MACRO PID ; part id 1=1..10 2=11..20 etc.
SET PID = PART - 1
SET PID = PID / 10
SET PID = PID +1
#ENDM
;Group B movement macros

#IF .__GROUP_B
;Check if Group B is Define
#MACRO MOVEDB
MOVED .1 .2
#ENDM
#MACRO MOVEB
MOVE .1 .2
#ENDM
#ELSE
#MACRO MOVEDB
#ENDM
#MACRO MOVEB
#ENDM
#ENDIF
;Synchronize macros
#MACRO STARTSYNC
SET $SYNC = 0
#ENDM
#MACRO SYNC ;Should be at the beginning of

;all the put programs.
WAIT $SYNC = 1 ;Wait to the end of get.
SET $SYNC = 0
#ENDM
#MACRO ENDGET ;At the end of all the get programs.

SET $SYNC = 1 ;Can start the put program.
#ENDM
;Gripper macros
#MACRO OPEN ;Open the gripper.
GOSUB OGRIP
#ENDM
#MACRO CLOSE ;Close the gripper.

GOSUB CGRIP
#ENDM
;Speed macros
#MACRO FAST ;Set group A and B speed to fast.

.FASTA
.FASTB

OpenCIM Programming
#ENDM
#MACRO MEDIUM ;Set group A and B speed to medium.

.MEDIUMA
.MEDIUMB
#ENDM
#MACRO SLOW ;Set group A and B speed to slow.

.SLOWA
.SLOWB
#ENDM
#MACRO FASTA ;Set group A speed to fast.

SPEEDA SPFA
#ENDM
#MACRO MEDIUMA ;Set group A speed to medium.

SPEEDA SPMA
#ENDM
#MACRO SLOWA ;Set group A speed to slow.

SPEEDA SPSA
#ENDM
#IF .__GROUP_B
;Check if group B is define.
#MACRO FASTB ;Set group B speed to fast.
SPEEDB SPFB
#ENDM
#MACRO MEDIUMB ;Set group B speed to medium.

SPEEDB SPMB
#ENDM
#MACRO SLOWB ;Set group B speed to slow.

SPEEDB SPSB
#ENDM
#ELSE
#MACRO FASTB ;Set group B speed to fast.
#ENDM
#MACRO MEDIUMB ;Set group B speed to medium.

#ENDM
#MACRO SLOWB ;Set group B speed to slow.

#ENDM
#ENDIF
;Programs macros (for GTxxx and PTxxx).

#MACRO PROGRAM ;The header of all the programs.
PROGRAM .1
DEFINE $I
#ENDM
#MACRO PROGRAM_GET ;The header of get programs.

PROGRAM GT.1
DEFINE $I
SET $I = 1
.STARTSYNC
#ENDM
#MACRO PROGRAM_PUT ;The header of put programs.

PROGRAM PT.1
DEFINE $I
SET $I = 1
#ENDM
#MACRO END_GET ;The tail of get programs.

.ENDGET

OpenCIM Programming
END
#ENDM
#MACRO END_PUT ;The tail of put programs.

END
#ENDM
;Controller D.D protocol macros

#MACRO GETID ;Get ID from D.D to $ID
LABEL 11
READ "?%ID?" $ID
IF $ID = 0 ;Check if the ID is zero (invalid).
GOTO 11
ENDIF
SET $I = 1
#ENDM
#MACRO GETIDL ;Get local ID for a not PCPLC program.

LABEL 11
DEFINE $IDL ;$IDL hold the local ID (instead of $ID).
READ "?%ID?" $IDL
IF $IDL = 0 ;Check if the ID is zero (invalid).
GOTO 11
ENDIF
DEFINE $I
SET $I = 1
#ENDM
#MACRO GETPAR ;Get Parameter from D.D.

PEND $PDF FROM $PDD
PRINTLN
READ "?%PAR?" .1
PRINTLN
POST 1 TO $PDD
#ENDM
;Controller manager protocol macros for global ID

#MACRO START ;Send start to manager.
PEND $PDF FROM $PDD
PRINTLN
PRINTLN "%START" $ID
PRINTLN
POST 1 TO $PDD
#ENDM
#MACRO FINISH ;Send finish to manager.

PEND $PDF FROM $PDD
PRINTLN
PRINTLN "%FINISH" $ID
PRINTLN
POST 1 TO $PDD
#ENDM
#MACRO END ;Send end to manager.

PEND $PDF FROM $PDD
PRINTLN
PRINTLN "%END" $ID .1 .2
PRINTLN
POST 1 TO $PDD
#ENDM
#MACRO QC ;Send quality control result to manager.

PEND $PDF FROM $PDD
PRINTLN
PRINTLN "%QC" $ID .1 .2
PRINTLN
POST 1 TO $PDD
#ENDM

OpenCIM Programming
#MACRO ERROR ;Send robot error message to manager.
PEND $PDF FROM $PDD
PRINTLN
PRINTLN "%ERROR " $ID .1 .2
PRINT .3
PRINT ".4 .5 .6 .7 .8 .9"
PRINTLN
POST 1 TO $PDD
#ENDM
;Controller manager protocol macros for local ID

#MACRO STARTL ;Send start of local program to manager.
PEND $PDF FROM $PDD
PRINTLN
PRINTLN "%START" $IDL
PRINTLN
POST 1 TO $PDD
#ENDM
#MACRO FINISHL ;Send finish of local program to manager.

PEND $PDF FROM $PDD
PRINTLN
PRINTLN "%FINISH" $IDL
PRINTLN
POST 1 TO $PDD
#ENDM
#MACRO ENDL ;Send end of local program to manager.

PEND $PDF FROM $PDD
PRINTLN
PRINTLN "%END" $IDL .1 .2
PRINTLN
POST 1 TO $PDD
#ENDM
#MACRO QCL ;Send quality control result of local

;program to manager.
PEND $PDF FROM $PDD
PRINTLN
PRINTLN "%QC" $IDL .1 .2
PRINTLN
POST 1 TO $PDD
#ENDM
#MACRO ERRORL ;Send robot error message of

;local program to manager.
PEND $PDF FROM $PDD
PRINTLN
PRINTLN "%ERROR " $IDL .1 .2
PRINT .3
PRINT ".4 .5 .6 .7 .8 .9"
PRINTLN
POST 1 TO $PDD
#ENDM
;Controller Other Devices protocol macros

#MACRO STOP ;Stop a device (like conveyor) or pcplc
process.
STOP GT.1
STOP PT.1
#ENDM
#MACRO CNCREQ ;Request from VC2_CNC

PEND $PDF FROM $PDD
PRINTLN
PRINTLN "%CNCREQ .1 .2 .3 .4 .5 .6 .7 .8 .9"
PRINTLN
POST 1 TO $PDD
#ENDM

OpenCIM Programming
#MACRO CNCSTR ;String to VC2_CNC
PEND $PDF FROM $PDD
PRINTLN
PRINTLN "%CNCSTR .1 .2 .3 .4 .5 .6 .7 .8 .9"
PRINTLN
POST 1 TO $PDD
#ENDM
#ENDIF
The file WS1.DNL contains sample ACL source code. This is the type of file you would edit
when you want to change the way a robot moves.

OpenCIM Programming
ACL System Programs
The .\LIB\ACL directory contains the file CIMSYS.SYS. This file includes system programs
for:
Name Identity Explanation
(TP Run #)
HOMES 1 Prepares the robot to work in the OpenCIM environment.
CIM 2 Reserved for future use.
RESET 3 Resets the variables and the programs.
CLEAR 4 Reserved for future use.
CIMP 5 Attaches the vectors CIM and CIMB to the teach pendant.
USER1 6 User-defined program.
INIT 10 Reserved for future use.
OGRIP 11 Opens the gripper.
CGRIP 12 Closes the gripper.
DIAG 13 The ACL device driver runs this program when it receives an asterisk
(*) from the controller (Diagnostic).
PCPLC 14 The ACL device driver runs this program in order to download
OpenCIM parameters to the ACL controller (Pick-and-Place).
$REST 15 The system reset program.
AUTO 16 This program runs each time the device driver is loaded and the ACL
controller is turned on.
INITC 17 This program is activated each time you load the ACL device driver.
If you want to modify one of the ACL System program files, enter these changes in the unique
PROLOGn.DNL file only.
Note

OpenCIM Programming
ACL Variables
In the ACL controller there are three types of global variables and two types of local
variables.
The global variables are:
ACL Controller System Variables
IN[16] Input status
ENC[6] Encoder
TIME Time
LTA Last time for group A
LTB Last time for group B
MFLAG Motion Bitmap
ERROR Error
OUT[16] Output status
ANOUT[6] Direct analog current to axis
For more information refer to the ACL Reference Guide.
ACL Controller User Variables (OpenCIM System Variables)
ERRPR Error program
ERRLI Error line
$SYNC Synchronization
$PDD Pend/ post printing to ACL programs
$PDF Pend/ post printing to ACL programs
SPFA Speed fast group A
SPMA Speed medium group A
SPSA Speed slow group A
SPFB Speed fast group B
SPMB Speed medium group B
SPSB Speed slow group B
$ID ID message number from the ACL device driver
PART Part number
PID Part ID group
$DEV1 Get device number
$DEV2 Put device number
INDXG Get device index
INDXP Put device index
$NOTE Note number
P1 Last position in the device group A
P2 Position before P1

OpenCIM Programming
TB Time needed for group B
NEWB New group B position
LASTB Last group B position
KB Time constant variable for group B
$NEW Temporary new position for group B
$LAST Temporary last position for group B
PB1 Last position in the device group B
PB2 Position before PB1
PB3 Position before PB3
ACL Controller User Variables (OpenCIM User Variables)
Note : From the ATS, type LISTVAR to display a list of variables.

The local variables are:
OpenCIM Local System Variables (ACL Controller Variables)
$I
$IDL $ID Local
OpenCIM User-Defined Local Variables (ACL Controller
Variables)
If you want to modify one of the ACL System program files, enter these changes in the
unique PROLOGn.DNL file only (e.g. If you want to change the SPFA, go to the
EPILOGn.dnl file and type SETSPFA=80).
PROLOG (PROLOGn.DNL)
In the PROLOGn.DNL file you can modify system programs, such as Global System
variables (e.g. SPSA - speed slow group A), predefined positions or any other settings that
need to be predefined for a particular station.
The following examples show how the PROLOGn.DNL file can be modified:
Modify Operating System Programs

; ********* HOME ************
PROGRAM HOMES /Y
* HOMING THE ROBOT
HOME
* HOMING THE L.S.B
HHOME 7
END
Define Positions
The principle here is to have fewer positions for better performance and faster
backup/restore.
Definition of a CIM position vector: P= lower point, P+10= highest point.

OpenCIM Programming
In the file PROLOG.DNL, all the positions are as follows:
1. Divide all of the positions into groups of 10 (ten).
2. The template positions 1 through 20 are for conveyors and buffers (e.g. conveyor 1/11,
first buffer 2/12, etc.).
3. Put=Get + 100
4. The last two spaces are used for OPENSPACE and OPENSPACE FOR TEMPLATE.
Example of how to define a position:
;********** POINTS **********
DIMP CIM[xxx]
; CIM:
; 1..9 P1 TEMPLATE
; 10..19 P2 TEMPLATE
; 21..29 P1 GET PART FROM BFFR1
; 31..39 P2 GET PART FROM BFFR1
; 41..49 P1 GET PART FROM
; 51..59 P2 GET PART FROM
; 61..69 P1
; 71..79 P2
; 81..89 P3
; 90..91
; 92..93
; 101..109 P1
; 111..119 P2
; 121..129 P1 PUT PART AT BFFR1
; 131..139 P2 PUT PART AT BFFR1
; 141..149 P1 PUT PART AT ASMBUF
; 151..159 P2 PUT PART AT ASMBUF
; 161..169 P2 OPENSPACE
; 171..179 P1 OPENSPACE FOR TEMPLATE
; 181..189 FREE
; 191..199 FREE
GET/PUT Programs
The GET/PUT.DNL files contain the pick-and-place programs.
GET/PUT Program Structure

The following table shows the sample GET and PUT programs found in the file *.DNL. The
customization instructions explain how to add your own code to complete these programs.
Example Programs Customization Instructions
.PROGRAM_GET xxx Replace the xxx with the device ID as defined in
DEVICE.DMC.
; move robot Insert a command to quickly move the robot to a
point above the source device (in the Free
Movement Zone).
; grab part/template Insert commands to lower the robot arm to the
source device and grab the part/template. Use the
part ID and index parameters (PART, INDXG) as
needed to grab the object.
; move robot Insert commands to move clear of the source
device.
.START This macro informs the CIM Manager that the
source device is free.
; move robot Insert commands to continue moving the robot to a
point above the source device (in the Free
Movement Zone) where the PUT program will take

OpenCIM Programming
Example Programs Customization Instructions
over.
.END_GET This macro activates the PUT program.
.PROGRAM_PUT xxx Replace the xxx with the device ID as defined in
DEVICE.DMC.
.SYNC This macro waits for the GET program to finish
moving the robot that is carrying the part/template
into position.
; move robot Insert a command to quickly move the robot to a
point above the target device (in the Free
Movement Zone).
; move robot Insert commands to lower the robot arm to the
target device. Use the part ID and index parameters
(PART, INDXP) as needed to set the part/template
in its place.
; deliver Insert commands to move clear of the target
part/template device.
.FINISH This macro informs the CIM Manager that the part
is in place and the target device is ready to be
activated.
; move robot Insert commands to move the robot to its standard
idle position (in the Free Movement Zone).
.END This macro informs the CIM Manager that the
robot is ready to perform the next GET operation.
.END_PUT
The following figure shows an example of GET and PUT programs after customization.
.PROGRAM_GET .ASRS
.FAST
MOVED CIM[11]
.SLOW
.OPEN
MOVED CIM[1]
.CLOSE
MOVED CIM[11]
.START
.END_GET
.PROGRAM_PUT .ASRS
.SYNC
.FAST
MOVED CIM[11]
.SLOW
MOVED CIM[1]
.OPEN
MOVED CIM[11]
.FINISH
.END
.END_PUT
Figure 11-4: Sample GET and PUT Programs After Customization

OpenCIM Programming
Synchronizing the GET and PUT
The ACL device driver activates the appropriate GET and PUT programs simultaneously.
Since a robot must first pick up a part before it can place it, the GET program must execute
before the PUT program. A synchronization mechanism is used to suspend the PUT program
until the GET program is finished.
The synchronization mechanism is handled automatically with macros if you base your ACL
programs on the sample GET and PUT programs found in CIMACL.DNL. The following
sample code shows the synchronization code after macro expansion.
PROGRAM GT001 - Get Template from Conveyor
*******************************************
Set $SYNC = 0. ; causes PUT program to wait
.
.
Set $SYNC = 1 ; activates PUT program
End
PROGRAM PT001 - Put Template in Buffer

****************************************
Wait $SYNC = 1 ; wait for GET program to set activate flag
Set $SYNC = 0 ; reset the activate flag
.
.
Figure 11-5: Synchronization Example for GET & PUT (Object Code)
QC Programs
The ACL can only hold integers. If you want to test integer quality control, you can send
your QC result to the ACL device driver (Barcode) once. If you want to test a decimal
number you need to send it string by string.
Integer Quality Control
ACL Source ATS / ACL Controller
Format*.QCL Format *.CBU Format
.PROGRAM QC PROGRAM QC 1. Receives the ID message
.GETIDL ***************
LABEL 11
number from the ACL device
READ ?%ID? driver.
$IDL
IF
$IDL = 0
GOTO 11
ENDIF
SET $I = 1
. . 2. Process to read the QC test.
. .
. .
ACL Source ATS / ACL Controller

Format*.QCL *.CBU Format
Format

OpenCIM Programming
SET QCRES = xx SET QCRES = xx 3. This variable receives the QC
.QCL QCRES PEND
$PDF FROM $PDD
result. You send the result to the
PRINTLN ACL device drivers.
PRINTLN
%QC $IDL
QCRES
END PRINTLN
POST
1 TO $PDD
ENDIF
END
4.
I. The CIM Manager sends two
values (a package), a higher limit
and a lower limit. Each package
has its own sequence # so that it
can be identified by the ACL
device driver. These are the
values that you defined in the
Part Definition form and in the
field parameters.
II. The ACL device driver sends the
sequence # for the package via
the RS232 link to the ACL
controller.
III. The ACL controller runs a QC

test and receives a value. This
value is sent back to the ACL
device driver.
IV.The ACL device driver verifies
that the value it received is within
the higher and lower limits of the
original package (values) sent. If
the value is within the limits, then
the ACL device driver sends a
message that the QC is OK. If the
value is not within the limits then
the ACL device driver sends a
FAIL message.
Process Programs
The Process programs include all of the utility programs necessary to operate the ACL
Input/Output (e.g. if you want to open the door of a CNC).
EPILOG (EPILOGn.DNL)
The EPILOGn.DNL file can be used to modify initialization system programs (INITC,
RESET) in the following ways:
ACL Source Format ATS /ACL Controller
EPILOGn.DNL *.CBU Format
PROGRAM RESET
PROGRAM RESET /Y *********************
GOSUB $REST

OpenCIM Programming
ACL Source Format ATS /ACL Controller
EPILOGn.DNL *.CBU Format
GOSUB $REST GOSUB BCOFF
GOSUB BCOFF STOP RVP
STOP RVP DELAY 50
DELAY 50 RUN RVP
RUN RVP DELAY 50
DELAY 50 GOSUB SEMER
GOSUB SEMER END
END
PROGRAM INITC
*********************
PROGRAM INITC /Y
STOP RVP
STOP
DELAY 30
RVP
RUN RVP
DELAY 30
STOP GT001
RUN RVP
STOP PT001
.STOP .CNV1
STOP GT003
.STOP .ASRS
STOP PT003
.STOP .BFFR1
.STOP .FDR1 STOP GT005
.STOP .RACK1 STOP PT005
.STOP .RDR1 STOP GT006
.STOP .TRASH1 STOP PT006
.STOP .ASMBUF STOP GT008
POST 1 TO $PDD STOP PT008
STOP GT009
GOSUB SEMER
STOP PT009
END
STOP GT007
STOP PT007
STOP GT004
STOP PT004
POST 1 TO $PDD
GOSUB SEMER
END
ACL Off-Line Utilities

OpenCIM requires the use of the ACLoff-line utility program version 1.65 or later. The
following ACL features are used when writing structured ACL code for OpenCIM:
Symbolic constants (#DEFINE)
User defined macros (#MACRO, #ENDM)
Include files (#INCLUDE)
Download Flags
# IF
# IFDEF
# IFNDEF
# ELSE
# ENDIF
Parameter passing using global variables.
Synchronization between programs running simultaneously.
Using the ACLoff-line utility program to send ACL source code to
the ACL controller.
You should be familiar with the system information contained in the include files
CIMSYS.SYS and CIMSYS.DMC before you start writing your own ACL programs for the
OpenCIM environment. This file contains system macros, programs, and global variable
definitions which perform the following functions:

OpenCIM Programming
Synchronize the running of GET and PUT programs.
Start and end GET and PUT programs.
Error handling.
Send status messages to the CIM Manager, to a CNC machine, and to
other CIM entities
You should NOT edit the CIMSYS.SYS or CIMSYS.DMC files without guidance from
Caution Intelitek technical support.
The program DOWNLOAD.EXE sends ACL source code files to the controller. While it is
sending programs to the ACL controller, this downloader checks syntax and substitutes the
program code associated with #DEFINE, #MACRO, and #INCLUDE. These three language
directives function similarly to their counterparts in C or Assembly language. For more
details, see the ACLoff-line program Users Manual and the ACL Reference Guide.
You must run the DOWNLOAD utility program on the Station Manager PC that is connected
to the controller in order to download programs (because the downloader requires an RS232
Note connection to the controller). However, the ACL source code files can reside on any PC
accessible via the network. Before trying to download code with the DOWNLOAD utility, be
sure to close the ACL device driver for this controller. Otherwise, a conflict will occur when
the ACL program tries to open the same serial port as the device driver.
Robot Programs
The Robot Programs consist of all the relevant programs necessary to run the robot. These
programs are divided into two categories: generic and unique, generic referring to the fact
that the program can be used by all the robots and unique referring to programs that are
specific for the robot at that station.
The Robot Programs are located in two places:
Generic Windows XP: [default system drive (for example C:)]\Documents and
Settings\All Users\Documents\Intelitek\OpenCIM\Projects\LIB\ACL
C:)]\Users\Public Documents\Intelitek\OpenCIM\Projects
Unique \Project#\WS#\ROBOT#
The following tables describe the file name conventions used for the ACL system programs
and sample applications supplied with OpenCIM. You should use these naming conventions
in your own programming to simplify technical support. You can use the ACL off-line
utility, the Robot Programs window or the text editor of your choice to edit these files.
We recommend that you use a Robot Programs window when editing these files. Save the
files in ASCII format.
It is recommended that you add a Robot Programs program group on a Station Manager
PC. This group should contain the following icons, as shown in the figure below.
Tip
ATS: Terminal emulation program which allows you to interact with the ACL
controller connected to a Station Manager PC.
Download: Sends ACL programs from a Station Manager PC to an ACL Controller.
Download Report:
Notepad WS1: Allows easy editing of a stations configuration file.
Additional Notepads: for editing other .DNL files.

OpenCIM Programming
Figure 11-6: Robot Programs Group Window
Generic Robot Programs

File
Extension Meaning
*.DNB DowNload - ACL source Blocks that are later copied to the DNL.
*.DMC Defines & MaCros - An include file (library file) containing user-supplied
defines and macros. The contents of this file are inserted in a DNL file at
the point specified by an INCLUDE command.
*.SYS All of the SYStem programs necessary to operate and communicate in the
OpenCIM environment.
*.QCB All the Quality Control Block programs and Communication Block
programs necessary for peripheral devices that connect directly to the ACL
controller.
*.PRB All the Process Block programs necessary to Communicate with devices
(e.g. CNC machine).
*.DLD DownLoad utilities.
Unique Robot Programs

File
Extension Meaning
*.DNL DowNLoad - ACL source code file that is sent to an ACL controller using
the ACL Downloader.
*.QCL This file is copied from a QCB file. After the original file is modified to
the editing application, the file is then unique to the specific QC device.
*.PRL This file is copied from a PRB file. After the original file is modified to the
editing application, the file is then unique to the specific process activation
(e.g. a program that speaks through I/O with a CNC machine).

OpenCIM Programming

1. In the Robot Programs window, select the Edit icon for the file
you want to edit; the file is displayed.
Procedure
Editing and 2. Edit the file.
Downloading a Robot
Program Separately
3. Select the Download icon for the file you just edited; the file is
downloaded to the controller.
4. Select the Download Report icon . Verify that the file ends with
>>>>>END DOWNLOAD FILE! Device file name

Note
If any Robot program files need to be edited, edit them before downloading.
Procedure
Downloading All of
the Robot Programs at
One Time In the Robot Programs window, select the Download Station icon ;
the files for the entire station are downloaded to the controller. When the files
are downloaded together, they are sent in the following order:
1. CIMSYS.SYS
2. PROLOGn.DNL
3. DEVICES.DNL, DEVICES.QCL and DEVICES*.PCL
4. EPILOGn.DNL
You should not edit ACL object code by using the ATS utility or by backing up a program
from a controller and modifying it. Either of these methods would result in an ACL file that
is very difficult to maintain.
Editing ACL object code (i.e. an *.CBU file) from the controller results in a program which
is out of sync with the original DNL file. This code is harder to read since all #DEFINE,
#MACRO, and #INCLUDE statements have been expanded in the controller and all remarks
have been deleted.
Note that the ATS utility can still be used for the following functions in the OpenCIM
environment:
Configure the controller
Back up and restore robot positions and downloaded ACL programs
Teach robot positions
Test a robot
Debug ACL programs by running them manually
Adding a New Pick-and-Place Operation

When you add a new device at a station (e.g. CNC machine, storage rack, assembly jig, etc.),
you must write two new ACL programs (GTxxx and PTxxx) that enable a robot to pick up
and deliver parts (or templates) from this device.
A program which directs a robot to pick up a part/template from a specific location is called
GTxxx. The xxx represents the unique three-digit device ID for a source location that is
found in the file SETUP.CIM.

OpenCIM Programming
Similarly, a program which directs a robot to deliver a part/template to a specific location is
called PTxxx. Once again, xxx represents a unique device ID, this time for the
target location.
For each pick-and-place operation, the CIM Manager sends a set of parameters to the ACL
controller. The ACL program PCPLC reads these parameters from the ACL device driver
and assigns them to a set of global variables. These variables are used to pass the parameters
to the appropriate GET and PUT programs.
A GET programs main function is to pick up a part/template, which involves the following:
Direct the robot to grasp a part/template
Move the robot to a safe position; clear of the source device
Send a Start status message
Continue moving the robot to an intermediate point from which it can
reach any device
Activate the PUT program
A PUT programs main function is to place a part/template in a designated location. This
operation involves the following steps:
Wait for an activation signal from a GET program
Move the robot to the target location
Set the part/template down at the target location
Move the robot clear of the target device
Send a status message that the part/template is in place and ready to
be processed
Move the robot to safe position from which it can reach any device
Send a status message that the robot is ready to perform the next
operation
To write a set of GET and PUT programs for a new device that has been defined in
SETUP.CIM, follow the steps outlined below:
Summary Details
1. Add the device to the 1. Use a text editor to insert a symbolic constant into the
file DEVICE.DMC file DEVICE.DMC. For example:
(connects the name of #DEFINE ASRS 002
the device and the # In this example, 002 is the device ID (3 digits required)
of the device). and ASRS is the symbolic name you will use throughout
your ACL programs to refer to this device.
It is much easier to maintain ACL programs that use
symbolic constants (e.g. .ASRS) instead of literal device
IDs (002). If a device ID ever changes, it is only necessary
to make the change in one place, i.e. in the file
DEVICE.DMC.
You should observe the following conventions when
assigning device IDs in order to simplify technical support:
001 Pallet at this conveyor station
002 ASRS (or other central storage)
2. Copy the files from 1. If you have a workstation with an ACL robot then add
..\LIB\ACL to the directory ROBOTn.
..WSn\ROBOTn
2. Copy the files from ..\LIB\ACL as follows:

OpenCIM Programming
Summary Details
2.1. If the Type (FLD #5) from SETUP.CIM is:
A, B, C, D, F, K, L, Q, J, M, S, X, Y, Z, then copy
from: to:
..\LIB\ACL\WS.BLK ..\WSn\ROBOTn\WSn.DNL
..\LIB\ACL\PROLOG.BLK
..\WSn\ROBOTn\PROLOGn.DNL
..\LIB\ACL\EPILOG.BLK
..\WSn\ROBOTn\EPILOGn.DNL
..\LIB\ACL\CONFIG.DLD
..\WSn\ROBOTn\CONFIG.DLD
Refer to OpenCIM Setup File: SETUP.CIM for more
information.
(Physical Name is FLD #3, Logical Name is FLD #4)
Rules for Creating DNL Files
2.2 If the Object Type in the SETUP.CIM (FLD #5)
is:
A, B, C, D, F, K, L, J, Q, M, S, X, Y, Z, then copy
from: to:
..\LIB\ACL\[FLD #3].DNB ..\WSn\ROBOTn\[FLD
#4].DNL
2.3 If FLD #5 is: L, Q or Y, then copy
from: to:
..\LIB\ACL\[FLD #3].QCB ..\WSn\ROBOTn\[FLD
#4].QC
2.4 If FLD #5 is: D or M, then copy
from: to:
..\LIB\ACL\[FLD #3].PRB to ..\WSn\ROBOTn\
3. Create two new 1. From the Robot Programs window, drag an icon; a new
icons: to edit the icon appears.
DNL and to 2. Select the new icon (click once) and press [Alt + Enter];
download the DNL. the Program Item Properties dialog box appears.
3. Type in the name of the new device in the Description
field.
4. Type in the name of the new device in the command line
for the Edit icon or type in the new Download file name
for the Download icon.
5. Select OK.

OpenCIM Programming
Summary Details
4. Editing the DNL, 1. From the Robot Programs window, select the icon of the
QCL and PRL files. file you want to edit; the file is displayed.
2. Type in the positions. Verify that the new positions you
are entering do not already exist and that all the details
of the position can be found in PROLOG.DNL.
3. Set the accurate speed.
Replace the xxx in the first line of the GET and PUT
programs with the device name that was defined in
DEVICE.DMC. Note the period preceding .PROGRAM
and the space and the period preceding the device name
(the leading period indicates a macro or symbolic
constant). For example:
Generic
Unique
.PROGRAM_GET xxx .PROGRAM_GET
.ASRS
.
.
.PROGRAM_PUT xxx .PROGRAM_PUT
.ASRS
1. Use a teach pendant (or other means) to train the robot

5. Use standard ACL
how to move and grasp.
procedures for
2. Enter the coordinates of the source and target locations
teaching a robot to
in the appropriate array.
grab and release a
3. Determine how the robot should grip the part/template.
part from the source
4. Fill in the appropriate robot movement commands in the
and target locations.
GET and PUT programs.
If the location has multiple compartments (or buffers), you can
use the variables INDXG and INDXP to help calculate the
array index for CIM[ ] (the array that contains all robot
positions). These index parameters specify the cell location
when dealing with a storage rack or ASRS.
When a robot wants to insert (or remove) a part in a CNC machine, it must tell the machine
when to open its door and chuck so the robot can enter the machine. The GET and PUT
programs associated with a CNC machine must communicate with CNC script programs that
open and close the door and chuck on the machine.

OpenCIM Programming
Robot Errors
Crash
When the ACL controller detects that a robot has collided with something, it responds as
follows:
The controller goes into COFF mode (Controller Off) and
immediately stops all motors on this robot.
The controller immediately terminates all programs which are trying
to move this robot. If any subsequent program attempts to move this
robot, it will terminate with a run-time error.
The ACL device driver automatically executes the DIAG program.
(This program should is loaded at initialization time as part of
CIMSYS.SYS.)
The DIAG program sends a status message to the CIM Manager to
reports the collision. See Sample ACL Programs, for a listing of
the DIAG program.
The CIM Manager displays the Device Error screen to alert the operator.
Emergency
Refer to your system user manual for details.

OpenCIM Programming
CNC Programming for OpenCIM
This section introduces the CNC script language and describes how to write CNC programs
in the OpenCIM environment.
CNC Script Language

This section provides an overview of the CNC script language and describes various
parameters, such as the initialization, parameters the system variables, CNC script error
messages and so on.
Introduction
The CNC Script Language is a language which allows you to write programs to control a
CNC machine. These programs can initiate machine operations by turning the machines
control lines on and off. Programs receive information from the machine via status lines.
These control lines and status lines are connected to a station manager PC via an interface
board. This board maps the control lines to output ports on the PC, and maps the status lines
to input ports. Each line corresponds to a bit in an I/O port. CNC script programs
communicate with a CNC machine by reading and writing these bits.
The CNC Script Interpreter is part of the CNC Device Driver. When the CNC Device Driver
receives a system message containing a CNC command, it finds the corresponding program
in the file CNC_SCR.DBF and runs it.
Language Overview
The following table lists the commands and parameter variables in the CNC Script
Interpreter:
Code Function
V1 - V16 Parameter variables read at initialization time.
P1 - P8 Parameter variables containing values passed to CNC script
programs at run time.
BV0, BV1 Current value of the two output ports.
PORT0, PORT1 PC I/O port addresses mapped to CNC control and status lines.
SetBit( ) Modifies the bits of the specified output port.
Wait( ) Suspends program execution for a specified duration.
WaitBit( ) Suspends execution until the specified bit(s) are set to one or
until the specified bit pattern appears on an input port.
WaitBitLow( ) Suspends execution until the specified bit(s) are set to zero or
until the specified bit pattern appears on an input port.
PulsBit( ) Turns on the designated bits of an output port for a specified
duration.
Draw( ) Prints a line to the screen.
Draw2( ) Prints two lines to the screen.
SendMsg( ) Sends a predefined message to another CIM entity.
DownLoadD( ) Sends a G-Code program to the CNC machine via RS232.
SendStr( ) Sends a string to the specified OpenCIM device (e.g. robot).
WaitStr( ) Suspends execution until the specified string arrives from the

OpenCIM Programming
Code Function
OpenCIM-CIM network.
WaitFile( ) Suspends execution until the specified file is created.
MSDOS( ) Performs any MS-DOS command.
MSWINDOWS( ) Launches any MS-WINDOWS executable file.
ABORT( ) Unconditionally aborts the current CNC device driver program.
Initialization Parameter Variables

The CNC Script Interpreter supports up to 16 general purpose parameter variables and two
special purpose variables which are defined at initialization time. The general purpose
variables contain values that are 0 to 80 bytes long. These variable names, V1 - V16, are
fixed. The two special purpose variables, PORT0 and PORT1, contain the addresses of I/O
ports used to interface to the CNC machine.
The CNC Device Driver assigns the values of the parameter variables V1-V16, PORT0, and
PORT1 at initialization time. It reads these values from the section
[CNCDriverDefinitions] in the file CNC.INI.
These variables are global to all CNC script programs.
Their values do not change during execution of a script
program.
General purpose variables can contain the following types of values:
Variable Range Example
Type
Integer Integers range in value from V8 = 60000
0 - 2,147,483,647
String A set of ASCII characters enclosed in quotation V1 = Door Open
marks. A string can range in length from 0 - 80
characters.
Bit Mask A string of 8 ASCII text characters enclosed in V16 = 01000111
quotation marks. Each character is either 0 or 1.
The following table describes the special purpose variables:
Variable Description Default Value
PORT0 The address of the first input and output ports on 0x500
the PC used to communicate with a CNC machine. (for both input and
output ports)
PORT1 The address of the second PC input and output 0x501
ports on the PC used to communicate with a CNC (for both input and
machine. output ports)
Passing Run-Time Parameters to Programs

Up to eight run-time parameters can be passed to a CNC script program. Each parameter
contains a value that is 0 to 80 bytes long. The parameter names, P1-P8 are fixed.
You specify a string of parameter values when you invoke a CNC script program.
Parameters in this string are separated by commas. The first value in the string is assigned to
the parameter variable P1, the second to P2, etc. The parameter string can be a maximum of
32 characters long (including the comma separators). The rules regarding parameter values
described in the previous section also apply to run-time parameter values.

OpenCIM Programming
The following sample parameter string contains both numeric and string values:
1000,Please wait,60,Finished
The way in which you specify the parameter string depends on which of the following
methods you are using to invoke the CNC script program:
Network Message A CIM message sent to a CNC Device Driver contains two strings,
the name of the CNC script program immediately followed by its
parameter string.
CNC Control Panel The string containing the list of parameters is specified in the
Parameters window of the Control Panel.
The CNC Device Driver initializes the values of run-time parameters read from the file
CNC.INI.
The values of run-time parameter variables do not change after they have been passed into a
CNC script program.
System Variables
System variables BV0 and BV1 are used to read the current value of their respective output
ports during execution of a script program. These variables are global to all CNC script
programs for a device driver.
These system variables are assigned in the device driver's INI file in the section
[CNCDriverDefinitions]. These 8-bit values, which range from 0255 are assumed
to be the initial state of the control lines of a CNC machine when the system is turned on.
The following table shows the CNC script system variables and their default values (i.e. the
values used if no assignment appears in CNC.INI):
System Variable Description Default Value
BV0 The current status (Port Value) of output port # 0. 0
BV1 The current status (Port Value) of output port # 1. 0
Command Arguments and Syntax

Numeric command arguments can take one of the following forms:
Integer 0 - 2147483647
Parameter Variable V1 - V16, P1 - P8
Spaces that appear in a commands argument list are ignored. Case is not significant in the
spelling of command names or for variable names in the argument list. The following
examples are equivalent:
SetBit(PORT1, BV1, &, V16)
SetBit (PORT1,BV1,&,V16)
Editing CNC Script Language Programs
All CNC script programs for a station (those that you write and those that come with the
system) are stored in the script file CNC_SCR.DBF. More than one CNC device driver can
share the same script file. This file normally resides either:
On the server in a subdirectory designated for this station
On the station manager PC running the CNC Device Driver
Use a dBASE editor to write your CNC programs to the appropriate CNC_SCR.DBF file. If
a CNC device driver is running, you must close it before you begin editing its
CNC_SCR.DBF file. Otherwise you will get an Access Denied error message.

OpenCIM Programming
Enter the name of each CNC script program in the REQUEST column. A program name can
be up to 32 characters long. It can contain any combination of letters, numbers, spaces, and
punctuation.
The ACTION column contains the CNC script commands that comprise a program. There is
no limit on the number of commands contained in a program.
The RETURN column is reserved for internal use. Do not enter any values in this column.
This file uses the following format:
REQUEST | ACTION | RETURN |
Program Name 1 | script command | 1 |
| script command | 2 |
End | | |
Program Name 2 | script command 1 | |
| script command 2 | |
| : | |
:

OpenCIM Programming
When the CIM Manager wants to run a CNC program, it issues a Run command to the
appropriate CNC Device Driver at a station. The device driver finds the program in the file
CNC_SCR.DBF and executes it.
Request Action
Return
go in RS232 receive pulsbit( port0, bv0, "00000001", 500 )

Draw("-- go to RS232 receive --")
end
go in auto pulsbit( port0, bv0, "00000010", 500 )
draw("-- go in auto --")
end
start for 0001 pulsbit( port0, bv0, "00000100", 500 )
draw("-- start for 0001 --" )
draw2( v16, "-- machine is running -- " )
end waitbit( port0, "00000001", 10000 )
open door pulsbit( port0, bv0, "00001000", 500 )
draw( "-- open door --" )
draw2( v16, "-- door is opened --" )
end waitbit( port0, "00000010", 10000 )
close door pulsbit( port0, bv0, "00010000", 500 )
draw( "-- close door --" )
draw2( v16, "-- door is closed --" )
end waitbit( port0, "00000100", 10000 )
open clamping device pulsbit( port0, bv0, "00100000", 500 )
draw( "-- open clamping device -- " )
draw2( v16, "-- clamping device is opened" )
end waitbit( port0, "00001000", 10000 )
close clamping device pulsbit( port0, bv0, "01000000", 500 )
draw( "-- close clamping device --" )
draw2( v16, "-- clamping device is closed" )
end waitbit( port0, "00010000", 10000 )
feedhold pulsbit( port0, bv0, "10000000", 500 )
draw2( "-- feedhold --", "*** ALARM ***" )
end waitbit( port0, "00100000", 10000 )
start for 0002 pulsbit( port1, bv0, "00000001", 500 )
draw( "-- start for 0002 --" )
draw2( v16, "-- machine is running --" )
end waitbit( port0, "00000001", 10000 )
pinole out pulsbit( port1, bv0, "00000010", 500 )
draw( "-- pinole out --" )
draw2( v16, "-- pinole is out --" )
end waitbit( port0, "01000000", 10000 )
pinole in pulsbit( port1, bv0, "00000100", 500 )
draw( "-- pinole in --" )
draw2( v16, "-- pinole is in --" )
end waitbit( port0, "10000000", 10000 )
Figure 11-7: Sample CNC Programs in the file CNC_SCR.DBF

OpenCIM Programming
CNC Script Error Messages
The error messages listed below appear in the CNC Status window when the CNC Script
Interpreter encounters an invalid statement.
"(" expected OR ")" expected A parenthesis surrounding the command's
argument list is missing.
End of program not found No End statement was found for the current
program in the Request column of
CNC_SCR.DBF.
Invalid command name The command name is not valid. Check the
spelling.
Program not found The program name is not valid. Check the
spelling.
Invalid system variable -
Use BV0 or BV1
Invalid bit mask The bit mask must be an 8-character string
composed of 1s and 0s.
Invalid port address - Use Replace the invalid address with the variable
PORT0 or PORT1 parameter
variable
PORT0 or PORT1.
OR
Check the value assigned to parameter variables
PORT0 and PORT1 in CNC.INI.
Unexpected number of arguments There are either too few or too many values in
the argument list for this command.
Unexpected string in argument An argument contains a string value instead of a
numeric value.
Unrecognized bitwise operator A character other than &, |, ^, or ~ was specified
as a bitwise operator.

OpenCIM Programming
CNC Script Language Commands
This section describes the CNC script language commands. Each of which is described in
detail in the following sections.
DownloadD()
DownLoadD( ) Sends a G-Code file to the CNC machine via RS232
Name: DownLoadD(FileName, MemArea)
Inputs: FileName Full DOS path of G-code 0 - 9999
program to be sent to the CNC
machine
MemArea Region in the CNC machine's 1 - 5
memory where this program is
to be loaded
Purpose
Normally a G-code file is assigned to a CNC process in the Machine Definition module. In
this case, the CIM Manager takes care of automatically downloading this file prior to
invoking the process and the DownLoadD( ) command is not needed. You should only
use the DownLoadD( ) command if you cannot set up a downloading batch file.
Function
The DownLoadD( ) command sends the G-code file FileName to the CNC machine
using the RS232 port specified in the device driver's command line. For machines capable of
retaining more than one program, you can specify the memory region where the current
program is to reside.
If the parameters Loader and TaskLoadedMark have been defined, the device driver
uses the batch file specified by Loader to perform the download (recommended).
Otherwise, the device driver's internal downloader is used.
Examples
DownLoadD(
Windows XP: [default system drive (for example
Users\Documents\Intelitek\OpenCIM\ WSn\filename,
C:)]\Users\Public Documents\Intelitek\OpenCIM\WSn\filename,
memory area (optional))
This statement sends the file MILLPART.G to memory region 1 in the CNC machine.
DownLoadD(P1, P2)
When testing a machine, the following statement receives the G-code file and memory
region that were defined in the Parameter field of the device driver's Control Panel.

OpenCIM Programming
Draw( )
Draw( ) Prints a line to the screen
Name: Draw(line_of_text)
Inputs: line_of_text String to display in the CNC 0 - 80 characters
Status window
Purpose
Viewing status messages during the operation of a CNC machine can be helpful in
troubleshooting problems and verifying the proper functioning of the machine. Messages can
also instruct the operator of the machine when a manual procedure must be performed.
These messages can be particularly helpful when dealing with machines which have either
no display of their own or only a very limited status panel.
Function
The Draw( ) command prints the string line_of_text in the CNC Status window. This
window appears on the PC running the CNC Device Driver. The Draw( ) command prints
each string on a new line.
The message string can be from 0 - 80 characters long. This argument can consist of either a
string literal enclosed in quotation marks (e.g. Drilling in progress) or a
parameter variable (V1 - V16, P1 - P8).
Examples
Draw(P3)
Draw(V5)
Draw(Door Open)
Draw2( )
Draw2( ) Prints 2 lines to the screen
Name: Draw2(text_line_1, text_line_2)
Inputs: text_line_1 First string to display in the 0 - 80 characters
CNC Status window
text_line_2 Second string to display in the 0 - 80 characters
CNC Status window
Purpose
When there is more than one line of text to display, it is convenient to use the Draw2( )
command to print two lines of text with one command call. Using the Draw2( ) command is
also faster than making two successive calls to the Draw( ) command. This can be an
advantage when running in a busy, real-time environment.
Function
The Draw2( ) command prints the strings text_line_1 and text_line_2 in the CNC
Status window. This window appears on the PC running the CNC Device Driver. The
Draw2( ) command prints each string on a new line.
Each message string can be from 0 - 80 characters long. These arguments can consist of
either a string literal enclosed in quotation marks (e.g. Machine overheated!) or a
parameter variable (V1 - V16, P1 - P8).

OpenCIM Programming
Examples
Draw2(P3, V2)
Draw2(V16, V5)
Draw2(Part ready, P8)
PulsBit( )
PulsBit( ) Turns on the designated bits of an output port for a specified duration
Name: PulsBit(portn, mask1, mask2, time_to_puls)
Inputs: portn Address of the output port to be 0x0000 -
modified 0xFFFF
mask1 An 8-character string 00000000 -
containing 1s and 0s 11111111
representing a bit mask. All V1 - V16
bits set to 1 are held high for P1 - P16
the duration of
time_to_puls.
representing a bit mask. All V1 - V16
bits set to 1 are held high for P1 - P16
the duration of
time_to_puls.
time_to_puls Number of milliseconds to CNCDriverTim
pause program execution while er - 2147483
asserting the specified high bits 647
V1 - V16
P1 - P16
Purpose
Some operations of a CNC machine are time-based as opposed to operations that signal their
completion via a status line. The PulsBit( ) command provides a convenient way of
executing an operation for a specified time period.
For example, after a part has been machined, it may be necessary to rinse it with water for 30
seconds before removing it from the CNC machine. The PulsBit( ) command can be
used to turn on the bit which controls the rinse cycle for the required period of time.
Function
The PulsBit( ) command gives you the means to control CNC operations for a specified
period of time. It turns on the designated bits of an output port for a specified duration.
The portn argument specifies the output port which contains the bit(s) that operate the
control line(s) you are interested in.
mask1 can be set to either:
The current value of the output port, BVn
An absolute bit mask value (see description of mask2 below)
You specify which ctrl lines should be pulsed on and off by constructing a bit mask, mask2.
The mask2 argument is an 8-character string composed of 1s and 0s in ASCII text. This
argument can consist of either a string literal enclosed in quotation marks
(e.g. 10000000) or a parameter variable (V1 - V16, P1 - P8).

OpenCIM Programming
The PulsBit( ) command performs a bitwise OR operation between mask1 and
mask2. It assigns the result to the output port for time_to_puls milliseconds. It then
resets the port to its original value. The minimum TIME_TO_WAIT is the value of the
parameter CNCDriverTimer found in CNC.INI.
The following table shows all the possible ways that PulsBit( ) can affect a single bit
position of an output port when mask1 = BVn:
PulsBit( )
Starting Value of Corresponding Bit Control Line During Control Line After
an Output Port Bit in Bit Mask Execution of Execution of
(mask1 = BVn) (mask2) PulsBit( ) PulsBit( )
0 0 0 - Off 0 - Off
0 1 1 - On 0 - Off
1 0 1 - On 1 - On
1 1 1 - On 1 - On
Examples
PulsBit(PORT0, BV0, 10000000, 30000)
This example turns on control line # 7 that is connected to the PCs output port 0 for 30
seconds. The remaining bits in the port retain their current values during and after execution
of PulsBit( ) since their values in the bit mask are 0.
PulsBit(PORT1, BV1, V5, 100000)
The bits in output port 1 are ORed with the bit mask in variable V5. The result is written to
output port 1 and the corresponding control lines are set on and off for 100 seconds.
Afterwards, the original value of output port 1 is restored.
PulsBit(PORT1, BV1, P4, P7)
The bits in output port 1 are ORed with the bit mask in parameter variable P4. The result is
written back to output port 1 and the corresponding control lines are set on and off for a
period of P7 milliseconds. Afterwards, the original value of output port 1 is restored.

OpenCIM Programming
SendMsg( )
SendMsg( ) Sends a predefined message to another CIM entity
Name: SendMsg(msg_to_send)
Inputs: msg_to_send Index to predefined messages 0 - 9999

stored in VC2_WM.DBF
Purpose
In a CIM environment, a CNC machine must report its status to other CIM entities such as:
The CIM Manager which handles production scheduling and
tracking
Devices which are dependent on this machine (e.g. the robot that
tends the machine)
The Graphic Production Module which displays the machines status
The SendMsg( ) command informs these entities when the CNC machine has completed
processing a part, when there is a problem that causes an alarm condition, etc. This
command uses a set of predefined messages to perform this function. Each message has an
associated ID and destination device address.
You can generate real-time status messages by inserting the SendMsg( ) command
throughout a program.
You can add your own custom messages to the message file. For example, this capability is
useful if you are programming a robot to tend this CNC machine. You could define a
message to notify the robot when the machine is ready to receive a part and another message
to inform the robot that the part is ready to be picked up. You would use the SendMsg( )
command to send these messages.
Function
The SendMsg( ) command sends predefined real-time status messages to any CIM entity.
The argument msg_to_send specifies the ID number of a message stored in the file
VC2_WM.DBF. This ID number is sufficient to deliver the message because there is a
destination address associated with each message in this file.
Examples
SendMsg(2582)
This statement finds the message with the ID number of 2582 in the file VC2_WM.DBF. It
then sends this message to the destination device listed in this message record.
SendMsg(P4)
SendMsg(V12)

OpenCIM Programming
SetBit( )
SetBit( ) Modifies the bits of the specified output port
Name: SetBit(portn, mask1, bo, mask2)
Inputs: portn Address of the output port to be 0x0000 - 0xFFFF
modified
representing a bit mask V1 - V16
(typically the current value of P1 - P16
output portn, BVn)
bo A single character designating & - AND
the bitwise operation to be | - OR
performed ^ - XOR
~ - NOT
representing a bit mask V1 - V16
P1 - P16
Purpose
The control lines of CNC machine are commonly mapped to bits in a PCs output port(s).
When a bit is toggled on and off, it controls the corresponding function on the CNC
machine. For example, suppose bit 3 is mapped to the door on the CNC machine. Setting bit
3 to one would close the door and setting it to zero would open the door.
By setting the appropriate bit(s) to the desired value, the SetBit( ) command allows you
to control a CNC machine.
Function
The SetBit( ) command allows you to modify a set of bits in an output port in order to
control the operation of a CNC machine.
The portn argument specifies the output port which contains the bit(s) that operate the
control line(s) you are interested in setting. Each I/O port on a PC contains 8 bits.
mask1 can be set to either:
The current value of the output port, BVn
An absolute bit mask value (see description of mask2 below)
Typically, mask1 would be set to the system variable BVn, the current value of the output
port. Using BVn allows you to set only the bits you are interested in while preserving the
values of the rest.
Alternatively, you could set the port to an absolute value by specifying a bit mask for mask1
instead of BVn. For example, to reset the port to a known value, you could specify the same
bit mask value for mask1 and mask2 and use an OR operation between them. This would
assign the value of the bit masks to the output port regardless of the ports previous value.

OpenCIM Programming
You can set the value of any group of bits in an output port by using the appropriate bit
mask, mask2, and bitwise operator, bo. The mask2 argument is an 8-character string
composed of 1s and 0s in ASCII text. This argument can consist of either a string literal
enclosed in quotation marks (e.g. 10000000), or a parameter variable (V1 - V16,
P1 - P8).
The following truth tables show the results of using each of the four C Language bitwise
operators available:
& - AND
Bit in mask1 Corresponding Bit Result after
in mask2 SetBit( )
0 0 0
0 1 0
1 0 0
1 1 1
| - OR
in mask2 SetBit( )
0 0 0
0 1 1
1 0 1
1 1 1
^ - XOR
in mask2 SetBit( )
0 0 0
0 1 1
1 0 1
1 1 0
~ - NOT
in mask2 SetBit( )
0 Not used 1
1 Not used 0

OpenCIM Programming
Examples
SetBit(PORT0, BV0, |, 10000000)
This example turns on control line # 7. This control line is connected to the PCs output port
0. The OR truth table indicates that when the mask contains a 1 in a given position, that bit
will be set to 1 regardless of the bits initial value in the output port.
SetBit(PORT1, BV1, &, V16)
The bits in output port 1 are ANDed with the bit mask in variable V16. The result is written
back to output port 1 and the corresponding control lines are set on and off accordingly.
SetBit(PORT1, BV1, ^, P8)
The bits in output port 1 are XORed with the bit mask in parameter variable P8. The result is
written back to output port 1 and the corresponding control lines are set on and off
accordingly.
Wait( )
Wait( ) Suspends program execution for a specified duration
Name: Wait(time_to_wait)
Inputs: time_to_wait Number of milliseconds to CNCDriverTim
suspend program execution er - 2147483
647,
V1 - V16,
P1 - P16
Purpose
After performing an operation on a CNC machine, it is sometimes desirable to pause for a
while before continuing with the next operation. For example, it may be necessary to wait 2
minutes after a certain procedure to allow a part to cool down before a robot extracts it from
the CNC machine. In this case the command Wait(120000) can provide the required
delay before the CNC script program signals the CIM Manager that the part is ready.
Function
When the CNC Script Interpreter encounters the Wait( ) command, it pauses for the
indicated amount of time before executing the next program statement. The argument
time_to_wait specifies the number of milliseconds the interpreter waits before resuming
execution. This argument can be either an integer or a parameter variable (V1 - V16,
P1 - P16). The minimum time_to_wait is the value of the parameter
CNCDriverTimer found in CNC.INI.
Examples
Wait(2000)
This statement causes the CNC Script Interpreter to pause for 2 seconds.
Wait(V16)
Wait(P8)
The length of the pause resulting from each of these two statements depends on the values of
variables V16 and P8.

OpenCIM Programming
WaitBit( )
WaitBit( ) Suspends execution until the specified bit(s) are set to one or until
the specified bit pattern appears on an input port
Name: WaitBit(portn, mask, time_to_wait)
Inputs: portn Address of the output port to 0x0000 -

be modified 0xFFFF
mask An 8-character string 00000000 -
containing 1s and 0s 11111111,
representing a bit mask V1 - V16,
P1 - P16
time_to_wait Maximum number of CNCDriverTim
milliseconds to suspend er - 2147483
program execution while 647,
waiting for a bit pattern V1 - V16,
P1 - P16
Purpose
After performing an operation on a CNC machine, it is frequently necessary to wait for a
status line to signal that the operation was successfully performed. Status lines from a CNC
machine are connected to an I/O board which maps each line to a bit in a PC input port.
By examining the value of these input port bits, it is possible to determine information about
a machine such as:
Status Line Example
An operation is completed. Bit 0
Drilling in progress = 0
Hole drilled = 1
An alarm condition has occurred. Bit 1
Normal temperature = 0
Machine overheated = 1
The position of a component on a CNC machine. Bit 2
Door open = 0
Door closed = 1
The WaitBit( ) command allows you to read a set of status lines in order to monitor the
operation of a CNC machine.

OpenCIM Programming
Function
The WaitBit( ) command monitors an input port, portn. It compares the value of this
port with the bit mask argument, mask. This command waits for the specified interval for
one of the following conditions to be true:
An exact match occurs between all 8 bits of the input port and the bit
mask.
A bit equal to 1 in mask matches up with the corresponding bit equal
to 1 in the output port. For example, bits 7 and 5 below meet this
condition:
10100000 mask
11110000 BVn
When one of these conditions is true, the Command Interpreter prints in the Status window:
--- Condition is true ---
It then proceeds to execute the next command.
The WaitBit( ) command monitors the port for the period of time specified in the
argument time_to_wait (in milliseconds). This argument can be either an integer or a
parameter variable (V1 - V16, P1 - P16). The minimum time_to_wait is the
value of the parameter CNCDriverTimer found in CNC.INI.
If neither of the above conditions occurs during this interval, the command times out. The
CNC Script Interpreter aborts program execution and generates the error message
WM_CIMDDE_CNCERROR. The CNC Device Driver relays this error message back to the
CIM Manager.
Examples
WaitBit(PORT1, 1000001, 2000)
This statement causes the CNC Script Interpreter to check port 1 for up to 2 seconds. If
status lines 0 and 7 in this port are high, the condition is true and execution resumes with the
next CLINT statement. If this match does not occur within 2 seconds, an error is generated.
WaitBit(PORT0, V3, P2)
The variables PORT0 and V3 contain the address of the input port and the bit mask
respectively. Variable V3 is assigned its value at initialization time from the file
VC2_CNC.INI. The time out interval, P2, is specified at run time when this program is
invoked.

OpenCIM Programming
WaitBitZ( )
WaitBitZ Suspends execution until the specified bit(s) are set to zero
Name: WaitBitZ(portn, mask, time_to_wait)
Inputs: portn Address of the output port to 0x0000 -
be modified 0xFFFF
mask An 8-character string 00000000 -
containing 1s and 0s 11111111,
representing a bit mask V1 - V16,
P1 - P16
time_to_wait Maximum number of CNCDriverTim
milliseconds to suspend er - 2147483
program execution while 647,
waiting for a bit pattern V1 - V16,
P1 - P16
Purpose
The WaitBitZ( ) command allows you to read a set of status lines in order to monitor the
operation of a CNC machine. See the WaitBit( ) command above for details.
Function
The WaitBitZ( ) command monitors an input port, portn. It compares the value of
this port with the bit mask argument, mask. This command waits for the specified interval
for one of the following conditions to be true:
An exact match occurs between all 8 bits of the input port and the bit
mask.
A bit equal to 1 in mask matches up with the corresponding bit equal to 0 in the output port.
For example, bits 5 and 7 below meet this condition:
10100000 mask
01011111 BVn
When one of these conditions is true, the Command Interpreter prints in the Status window:
--- Condition is true ---
It then proceeds to execute the next command.
The WaitBitZ( ) command monitors the port for the period of time specified in the
argument time_to_wait (in milliseconds). This argument can be either an integer or a
parameter variable (V1 - V16, P1 - P16). The minimum time_to_wait is the
value of the parameter CNCDriverTimer found in CNCVDn.INI.
If neither of the above conditions occurs during this interval, the command times out. The
CNC Script Interpreter aborts program execution and generates the error message
CIM Manager.

OpenCIM Programming
Examples
WaitBitZ(PORT1, 10000001, 2000)
This statement causes the CNC Script Interpreter to check port 1 for up to 2 seconds. If
status lines 0 and 7 in this port are low, the condition is true and execution resumes with the
next CLINT statement. If this match does not occur within 2 seconds, an error is generated.
WaitBitZ(PORT0, V3, P2)
The variables PORT0 and V3 contain the address of the input port and the bit mask
respectively. Variable V3 is assigned its value at initialization time from the file
CNCVDn.INI. The time out interval, P2, is specified at run time when this program is
invoked.
WaitFile( )
WaitFile( ) Suspends execution until the specified file is created
Name: WaitFile(String, time_to_wait)
Inputs: String Any valid MS-DOS file Any valid
name. MS-DOS file
name.
time_to_wait Number of milliseconds to CNCDriverTim
647,
V1 - V16,
P1 - P16
Purpose
The command is generally used to get a status message in order to continue execution of the
process after uploading a G-code program to a CNC machine.
Function
The WaitFile( ) command waits until the specified file is created during a specified
interval. If the specified file has not been created during the specified interval, the command
times out. The CNC Script Interpreter aborts program execution and generates the error
message WM_CIMDDE_CNCERROR. The CNC Device Driver relays this error message
back to the CIM Manager.
Examples
WaitFile(P1, V1)
WaitFile(V1, P1)
WaitFile(V1, V2)
WaitFile(P1, P2)
WaitFile(
Users\Documents\Intelitek\OpenCIM\ WSn\filename
C:)]\Users\Public
Documents\Intelitek\OpenCIM\WSn\filename), wait time)

OpenCIM Programming
WaitString( )
WaitString( ) Suspends execution until the specified string arrives from Network
Name: WaitString(String, time_to_wait)
Inputs: String A string that specifies the Any string
beginning or end of an that
operation. contains an
address in
the OpenCIM
environment.
time_to_wait Number of milliseconds to CNCDriverTim
647,
V1 - V16,
P1 - P16
Purpose
After performing an operation on a CNC machine, it is usually necessary to wait for a status
message in order to confirm that the operation was performed successfully.
Function
The WaitString( ) command waits for a string during a specified interval. If the CNC
device driver doesnt receive the string during the specified interval, the command times out.
The CNC Script Interpreter aborts program execution and generates the error message
CIM Manager.
Examples
WaitString(V1, V2)
WaitString(V1, P1)
WaitString(P1, V1)
WaitString(Test is done, 10000)

OpenCIM Programming
SendString( )
SendString( ) Sends a string to the specified OpenCIM device ( e.g. to a robot)
Name: SendString(Address, String)
Inputs: Address Name of the workstation in Any of the OpenCIM
the OpenCIM predefined commands.
environment.
String String to be sent to be sent Any string that contains an
to the defined address address in the OpenCIM
environment.
Purpose
When a program is to be run in the ACL controller, a string (recognizable by the ACL
controller) is sent to the ACL controller and the address tells the controller where to send the
string.
Function
The SendString( ) command sends predefined commands to any CIM entity.
Examples
SendString(P1, P2)
SendString(V1, V2)
SendString(V1, P1)
SendString(WS0 DDE ACL 25, RUN SSCNC)
MSDOS( )
MSDOS( ) Performs any MS-DOS command
Name: MSDOS(String)
Inputs: String Any valid MS-DOS Any valid MS-DOS
command. command.
Purpose
The command provides an interface from OpenCIM to the MS-DOS operating system.
Function
The MSDOS( ) command launches the MS-DOS command interpreter with the string
specified at the functions input.
Examples
MSDOS(V1)
MSDOS(P1)
MSDOS(LOADER.BAT FILE.DAT)

OpenCIM Programming
MSWINDOWS( )
MSWINDOWS( ) Launches any MS-WINDOWS executable file
Name: MSWINDOWS(String)
Inputs: String Any valid MS-Windows Any valid MS-Windows
command line. command line.
Purpose
The command provides an interface from OpenCIM to the MS-WINDOWS operating
system.
Function
The MSWINDOWS( ) command launches the MS-WINDOWS executable file according to
the string specified at the functions input.
Examples
MSWINDOWS(V1)
MSWINDOWS(P1)
MSWINDOWS([default system drive (for example
C:)]\WINDOWS\NOTEPAD.EXE
Users\Documents\Intelitek\OpenCIM\ WSn\filename
C:)]\Users\Public
Documents\Intelitek\OpenCIM\WSn\filename)
ABORT( )
ABORT( ) Unconditionally aborts the current CNC Device Driver program
Name: ABORT( )
Purpose
Using this command is the only way to abort a CNC Device Driver program without the
CIM Manager.
Function
The ABORT( ) command unconditionally aborts the current CNC Device Driver program.
Examples
ABORT( )

OpenCIM Programming
Robot and CNC Interface
When a robot inserts a part into a CNC machine, it must coordinate its movements with the
operation of the machine using a CNC synchronization mechanism. This mechanism is used
when a robot sends a command message to a CNC machine telling it to perform a certain
function. The robot then waits for a response. Only after the CNC responds does the robots
ACL program continue execution.
The following scenario describes how a typical robot and CNC machine interact when the
robot inserts and removes a part from the machine:
The robot waits while the CNC machine opens its door and vise.
The robot enters the machine. It holds the part in place while the
machine clamps the part in its vise.
The robot exits the machine and signals the CIM Manager that the
CNC machine is ready to be activated.
The robot waits outside the machine until it receives a signal from the
CIM Manager that the machine is finished.
The CNC opens its door and waits until the robot has grasped the part
before it opens its vise.
The robot removes the part and takes it to the next location.
While the CIM Manager could conceivably coordinate the above interaction between a robot
and a CNC machine, it is more efficient for the ACL controller to do this. This section
describes how to write ACL programs that communicate with script programs found in the
CNC device driver. (You should already be familiar with OpenCIM ACL programming
before continuing. See ACL Programming for OpenCIM for more information.)
The CNC synchronization mechanism is actually a specific case of how you can send
command and status messages to perform OpenCIM operations.

OpenCIM Programming
It is possible to have two robots attached to a single ACL controller. In this case, you would
use the ACL system file, CIMSYSM instead of CIMSYS. You would also need to adjust the
sample code presented in this section to distinguish between the two robots. These changes
are beyond the scope of this discussion.
The following diagram illustrates the sequence of commands that are executed when a robot
inserts a part into a CNC machine. The commands shown in step 2 below are generated by
the robots PUT program for the CNC machine.
Command Sequence:
. When the production plan calls for machining a part, the CIM Manager
sends a single command telling the tending robot to insert the part in the CNC
machine.
. The PUT program in the robot's ACL controller sends a series of
commands to open and close the door and the vise on the CNC machine so the
robot can insert the part.
. When the robot signals that the part is in place, the CIM Manager sends an
activate command to the CNC machine.
Figure 11-8: Sequence of Commands when a Robot Tends a CNC Machine

OpenCIM Programming
The following table describes the dialog that occurs between a robot and its CNC machine.
This table shows the sequence of CNC commands generated by the PUT and GET programs
that insert and remove a part from a machine.
Robot Action Robot CNC
Request Response
PUT Part into CNC Machine
Robot brings part to entrance of CNC machine and waits Open Door Door Open
for door to open.
Robot enters CNC machine with part and waits for vise to Open Vise Vise Open
open.
Robot places part in vise and waits for vise to close. Close Vise Vise Closed
Robot releases part, withdraws from CNC, and waits for Close Door Door Closed
door to close.
Robot signals CIM Manager that part is ready to be
machined. The CIM Manager turns on the CNC machine.
(The robot does NOT directly turn on the CNC machine
by sending an activate command. Instead, the CIM
Manager sends the activate CNC command message to the
machine so that it can take care of downloading the
G-code needed to process this part.)
GET Part from CNC Machine
Robot moves to entrance of CNC and waits for door to Open Door Door Open
open.
Robot enters CNC, grasps part, and waits for vise to open. Open Vise Vise Open
Robot removes part from CNC machine.

OpenCIM Programming
Writing Scorbase Programs for the CNC Machine
This section describes briefly how to write Scorbase programs for the CNC machine and
displays various examples. It includes the following:
Receiving Strings from an OpenCIM Device Driver
Receiving Notifications from the CNC Machine and Sending
Messages to the CNC Device Driver
Receiving Strings from an OpenCIM Device Driver
The Scorbase software automatically recognizes and executes the following two string
formats, for example:
SET PRGNM=301: In this string format, PRGNM is the name of the
Scorbase variable and this statement is equivalent to the Set
Variable PRGNM = 301 instruction in the Scorbase program.
This string is generally defined in the Program column of the CIM
Machine Definition utility in the CIM Manager application.
Run STRTM: In this string format, STRTM is the Scorbase
subroutine name and the string is equivalent to the Call STRTM
instruction in the Scorbase program. The Scorbase program should
contain the STRTM subroutine, as shown in the following example:
Set Subroutine STRTM
Print to Screen: STRTM.PRGNM = 'PRGNM'
Call Subroutine SCRIPT.OPENPORT (2)
Call Subroutine SCRIPT.SENDFILE(2, PRGNM)
Call Subroutine SCRIPT.CLOSEPORT(2)
The STRTM subroutine is executed in parallel to the Pick and Place operation of the robot
The STRTM subroutine does not contain axis control Scorbase commands.
Notes
The Run STRTM string is generally defined in the CNC device driver script file.

OpenCIM Programming
Receiving Notifications from the CNC Machine and Sending Messages to
the CNC Device Driver
The USB controllers digital input can be connected to the CNC machines digital output.
The CNC machines G-Code program may change the status of the digital output that is
connected to USB controller.
The Scorbase program can recognize changes to the status of the digital input and then run a
user defined subroutine (END_LATHE23), which can be executed in parallel to the Pick and
Place operation of the robot, as shown in the following example:

Print to Screen: PUT PART TO CNC MACHINE CHUCK (CNC22)
...
...
...
Enable Input Interrupt 1
On Input Interrupt 1 On Run Subroutine END_LATHE23
Send Message $Finish to MANAGER ID TASK_ID
Send Message $End to MANAGER ID TASK_ID
Set Subroutine END_LATHE23

Send Message ENDLATHE to Device Driver ID 23
Disable Input Interrupt 1
Pay attention to the Enable/Disable Input Interrupt instructions to ensure system safety.
Note

OpenCIM Programming
Writing ACL Programs for the CNC Machine
The CNC synchronization mechanism is used when a robot must order a CNC machine to
perform an operation and wait until the machine signals that it has completed the operation.
The previous table shows the sequence of events in a set of PUT and GET programs that
communicate with a CNC machine. The sample ACL code shown in this section
demonstrates how to write these programs and implement the CNC synchronization
mechanism.
You must code this synchronization mechanism into each of the following programs. Note
the order in which programs are activated as shown in the figure below.
ACL The PUT and GET programs which tell the robot how to insert and
Controller remove parts from a CNC machine.
CNC Device CNC script programs (executed by the CNC device driver) which are
Driver activated by a robot request. For example:
OPEN DOOR, CLOSE DOOR, OPEN VISE, CLOSE VISE
ACL A group of short ACL programs which set a semaphore variable that
Controller announces that the CNC machine has completed the requested operation
(e.g. DROPN - door open, DRCLS - door closed, VCOPN - vise open,
VCCLS - vise closed).
Figure 11-9: Sequence of Program Activation During CNC Synchronization

Sequence of Program Activation
1. RUN GTxxx Pick-and-place command from the CIM Manager runs the
RUN PT001 ACL program PT001 to insert a part into the CNC machine.
(The constant .CNC1 equals 001, the device ID of the
machine.)
2. .CNCREQ Activates CNC script program OPEN DOOR in CNC device
.CNC1 OPEN driver #1.
DOOR

OpenCIM Programming
3. SENDSTR(V1, Sends an acknowledgment by running the ACL program
"RUN DROPN. This line sends a run command to the ACL device
DROPN") driver whose address is specified in variable V1.
4. SET Causes the program PT001 to resume.
DOOR = OPEN
The following ACL statement sends a command to a CNC machine:
.CNCREQ .CNC1 OPEN DOOR
The macro and symbolic constant in this statement expand to:
PRINTLN "%CNCREQ 001 OPEN DOOR "
Each item in this statement is explained below:
ACL Statement that Requests a CNC Operation
PRINTLN This ACL command sends a message to the robot's ACL device
driver via a serial connection between the ACL controller and the
Station Manager PC.
%CNCREQ This string signals the ACL device driver that the rest of this
message is a command intended for a CNC machine. The ACL
device driver interprets and formats the message accordingly.
001 The device ID of the CNC machine that the robot is tending; used
as part of the destination address.
OPEN DOOR This string is the name of the script program which the CNC
device driver will execute. The robot waits until this script
program sends a response message indicating that it has finished
performing the requested CNC operation. You can check the
name of CNC script programs by looking at the Command List
on the CNC Control Panel.

OpenCIM Programming
When an ACL program needs to activate an operation on another device and wait for an
acknowledgment, it can use the CNC synchronization mechanism. The sample ACL code
below demonstrates an efficient way to implement this mechanism:
:
:
SET DOOR = 0 The global variable DOOR represents the status of the door on
the CNC machine. It can have one of the following values:
0 - Door status is about to change. CNC request is pending.

OPEN - Door is open.
CLOSE - Door is closed.
The variable DOOR is used as a semaphore to signal that the

CNC machine has completed the requested operation (i.e. when
a response has been received from the CNC machine). This
variable is reset to 0 here to indicate that a CNC request is
pending.
This line uses an ACL macro (explained above) to send the
command message "OPEN DOOR" to CNC machine #1.
WAIT DOOR = OPEN This line suspends execution of this ACL program until an
acknowledgment is received from the CNC machine.
(Note that this line does NOT assign the value of OPEN to the
: variable DOOR. The string DOOR = OPEN is a logical
: condition which must be satisfied before the WAIT statement
allows execution to continue.)
In this example, the CNC machine signals that the door is open by sending a command to the
ACL device driver to run a short ACL program, DROPN. This program sets the global
variable DOOR equal to OPEN. This assignment satisfies the WAIT condition and execution
continues.
The WAIT statement is more efficient than using a polling loop to continually check the
value of the variable DOOR. Unlike a loop, this statement suspends execution of the
Tip
program until the condition is satisfied. Suspending execution allows other active ACL
programs to run faster.

OpenCIM Programming
The following is a set of sample ACL programs: GET, PUT, DROPN, DRCLS, VCOPN,
and VCCLS. These programs insert and remove a part from a machine using the CNC
synchronization mechanism (the CNC synchronization code is highlighted):
.PROGRAM_GET .CNC1
.OPEN
.FAST
MOVED CIM[260]
MOVED CIMB[260]
MOVED CIM[260]
JAW 50
SET DOOR = 0
WAIT DOOR = OPEN
.MEDIOM
MOVED CIM[261]
SPLINE CIM 262 263
.MEDIOM
MOVED CIM[288]
.SLOW
MOVED CIM[289]
.CLOSE
SET VISE = 0
.CNCREQ .CNC1 OPEN VISE
WAIT VISE = OPEN
.MEDIOM
MOVED CIM[288]
.MEDIOM
MOVED CIM[262]
.FAST
.START
MOVED CIM[261]
MOVED CIM[260]
.END_GET
PROGRAM DROPN
SET DOOR = OPEN
END
PROGRAM DRCLS
SET DOOR = CLOSE
END
PROGRAM VCOPN
SET VISE = OPEN
END
PROGRAM VCCLS
SET VISE = CLOSE
END
.PROGRAM_PUT .CNC1
.SYNC
.FAST
MOVELD CIM[260]
IF PART = 2
ORIF PART =4
GOSUB GIJIN
ENDIF
MOVED CIM[260]
MOVED CIMB[260]
SET DOOR = 0;
WAIT DOOR = OPEN
.MEDIOM
MOVED CIM[261]
SPLINE CIM 262 263
SET VISE = 0

OpenCIM Programming
.CNCREQ .CNC1 OPEN VISE
WAIT VISE = OPEN
.MEDIOM
MOVED CIM[268]
.SLOW
MOVED CIM[269]
JAW 50
.MEDIOM
MOVED CIM[270]
.SLOW
.CLOSE
MOVED CIM[271]
SET VISE = 0
.CNCREQ .CNC1 CLOSE VISE
WAIT VISE = CLOSE
.MEDIOM
MOVED CIM[270]
MOVED CIM[262]
.FAST
MOVED CIM[261]
MOVED CIM[260]
MOVED CIMB[1]
SET DOOR = 1
.CNCREQ .CNC1 CLOSE DOOR
WAIT DOOR = CLOSE
.FINISH
.OPEN
.END
.END_PUT

OpenCIM Programming
Using CNC Script Programs for ACL Program Response
When a CNC script program has completed an operation requested by an ACL program, it
must send back an acknowledgment to the ACL program. The following script statement
sends this acknowledgment and is explained below:
SENDSTR (V1, "RUN DROPN")
SENDSTR Sends the acknowledgment message to the robot's ACL device
driver using the OpenCIM network.
V1 A script parameter variable containing the destination address of
the robot which is to receive this acknowledgment. This variable
is assigned in a parameter file (e.g. CNC1.INI) when the CNC
device driver starts up.
"RUN DROPN" A command to run the ACL program DROPN which sets a
semaphore variable indicating that the CNC door is open. This
ACL program name corresponds to the operation being
performed. For example: DRCLS - door closed
VCOPN - vise open
The following sample CNC script program shows how this statement appears at the end of
the script after the requested operation has completed:
PROGRAM OPEN DOOR
PULSBIT(PORT0,BV0,"00001000",600)
DRAW( --- OPENING THE DOOR --- )
WAITBIT( PORT0, "00000010", 20000 )
DRAW( --- DOOR IS NOW OPEN --- )
SENDSTR( V1, "RUN DROPN" )
END
Figure 11-10: Sample CNC Script Program that Sends an Acknowledgment to a

Robot
Writing Portable CNC Script Programs
If you have multiple CNC machines which use the same commands, you can reuse the same
CNC script file (e.g. CNC_SCR.DBF) to control these machines. Follow the example below
which shows how to write portable CNC scripts using a parameter variable to specify a
destination address:
Portable: SENDSTR (V1, "DROPN")
Not Portable: SENDSTR(WS3 ACL43, DROPN)
Use a text editor to assign V1 in a parameter file (e.g. CNC1.INI) as follows:
:
:
V1 = ACL43
:
:

OpenCIM Programming
The elements in this example are explained below:
WS3 The name of the Station Manager PC (as found in the file SETUP.CIM)
running the CNC device driver. Substitute the appropriate workstation
number for the 3 in this example.
ACL The type of communication channel used to send messages to this device.
Use ACL for any device attached to an ACL controller.
43 The device ID that indicates which device driver is to receive this
message. Substitute the device ID of the robot which tends this machine
for the 43 in this example.
Adjustments for Single Robots Tending Two Machines

If a single robot is tending two CNC machines, make the following adjustments to the
sample programs shown in this section:
In the ACL controller, use two separate global variables, DOOR1
and DOOR2, for each machine (instead of the single variable DOOR).

Use two separate ACL programs, DRON1 and DRON2, to set these
variables (instead of the single program DROPN).
The OPEN DOOR script programs on the CNC machines would call their associated ACL
program, DRON1 or DRON2.
ACL Controller Backup and Restore

Because there is always a chance that system files could be altered or destroyed, we
recommend keeping backup files of your OpenCIM system. Should your OpenCIM system
crash and need to be replaced, the backup files can be used to restore the system. These
procedures should only be performed by the system supervisor.
The Backup procedure involves three stages:
1. Back up the ACL controllers to the Station Manager PCs
2. Back up the Station Manager PCs to the CIM Manager PC
3. Back up the CIM Manager PC.
Do not perform Backup procedures while the OpenCIM is running because currently
running programs may be aborted and data files may be in an unstable state.
Note
Always keep robot positions, ACL programs and parameters on disk.
Back up and restore the entire system regularly to ensure good backup at all times.

OpenCIM Programming
How to Back Up an ACL Controller
An entire backup of the ACL controller includes all robot parameters, positions and
programs.
To back up the controller, do the following:
1. From the ATS main screen on the Station Manager PC, press [Shift +
F10] for Backup. The Backup Manager screen appears.

Procedure 2. Make sure the Backup Directory field is correct before proceeding.
Backing Up the ACL 3. Select Parameter in Backup/Restore.
Controllers 4. Type Parameter in the File Name field and press [Enter].
5. Press [F3] for backup; a warning message appears stating that All
running programs will be aborted. Are you sure
(Y/N)?
6. Type Y; asterisks appear and move across the bottom of the screen
representing a time bar. When the time bar lapses, Done appears on the
screen confirming that the backup copy has been completed successfully.
7. Press [Enter] until the cursor selects Positions in Backup/Restore.
8. Type Position in the File Name field and press [Enter].
9. Repeat steps 5 and 6 for the backup of Positions.
10. Press [Enter] until the cursor selects Programs in Backup/Restore.
11. Type Programs in the File Name field and press [Enter].
12. Repeat steps 5 and 6 for the backup of Programs.
13. Press [Enter] until the cursor selects All in Backup/Restore.
14. Type All in the File Name field and press [Enter].
15. Repeat steps 5 and 6 for the backup of All.
16. Verify that all the backup files you copied can be found in the WSn
Robotn directory. The backup file extension is .CBU (e.g.
POSITION.CBU).

OpenCIM Programming
Optimization Enhancement Using Open Source
The Optimization Manager of OpenCIM enables users to choose any combination of
algorithms and weights for the machine queues, using the algorithms supplied in the
installation.
Using Open Source in OpenCIM, the advanced programmer can add new algorithms to the
existing list. The new algorithms are automatically added to the OpenCIM Optimization
Manager. The user can then choose the new algorithms from the Algorithms drop down list
in the Optimization Manager and test them by running the OpenCIM Manager. The new
algorithm can use any of the parameters that are included in the OpenCIM database.
For detailed instructions on adding new algorithms refer to the ReadMe file that is provided
with the source files of the QueAlgDef project.

OpenCIM Programming
Experimenting with Production Strategies Using the
A-Plan
The A-Plan is a table of sequential instructions which the CIM Manager executes in order to
produce the products being ordered. It is created when you submit an order. You can also
edit this table manually with a z editor.
Just as you can compile and run a program without ever examining the associated assembly
code, so you can submit an order and run the OpenCIM production line without dealing with
the A-Plan. However, advanced users may want to understand the mechanics of OpenCIM
production in order to optimize certain critical areas. This section explains the structure of
the
A-Plan and how to modify it.
The A-Plan is based on processes and operations that have been set up in the Part Definition
table. For each ordered part, the A-Plan lists the procedures required to produce that part.
The relationship between the Part Definition table and the A-Plan is similar to the
relationship between source code written in a high-level programming language and the
resulting assembly language output after compilation. Dealing with the source code is the
easiest way to understand and change a program. However, dealing with the assembly
language output might be appropriate for advanced users who need to optimize certain
critical areas or who want to understand more fully what is happening at the hardware level.
Similarly, the Part Definition table provides an overview of the CIM production process
while the A-Plan lists the underlying details.
In addition to user-defined processes, the A-Plan includes the intervening steps required to
move parts from machine to machine and from station to station. When an order is
submitted, the Order Entry module automatically creates the A-Plan by combining the
appropriate material handling commands (described below) with the user-defined processes
from the Part Definition table.
A-Plan Commands
The following discussion of the A-Plan assumes that:
The default storage device is a single ASRS used to house empty
templates, raw materials, and finished parts.
The default assembly device is a jig machine which is used to hold
parts that are in the process of being put together by a robot.
The list below shows each command that can appear in the A-Plan table. Related commands
are grouped together. These groups are labeled in the Purpose column.
Purpose A-Plan Description
Command
Loop for Producing MAKE Defines the beginning of a loop used to produce the
Multiple Parts of the number of products ordered.
Same Type
NEXT Marks the point at which production of the next
ordered part begins. Note that production of the next
part may begin before the current part has finished.
Template Commands DELIVER Tells the PLC to stop a specific template at a station.
FREE Releases an empty template so it can be returned to
the ASRS.

OpenCIM Programming
Purpose A-Plan Description
Command
Assemble Two Parts BASE Commands a robot to place the first part to be
assembled in a jig. The CIM Manager waits for all
subparts that belong to this assembly to arrive before
placing the base part in the jig.
PACK Commands a robot to place a subsequent part to be
assembled onto the base part in the jig. The CIM
Manager waits for the Base command to finish before it
starts executing a Pack command.
ENDPACK Signals the end of an assembly operation.
Storage Commands GET Reserves a part that is being stored in the ASRS.
STORE Sends a part to the ASRS (or other storage location)
to be stored.
RENAME Assigns the name shown in the Part field to a
finished part. This command appears in the
A-Plan immediately after the last user-defined
process from a Part Definition table has been
performed.
Robot Commands PLACE Commands a robot to move a part or template from
one location at a station to another (i.e. a
pick-and-place operation). This command is used to
insert parts into devices such as a laser scan meter or
robot vision system. However, it is NOT used when
placing a part in an assembly jig (see Base/Pack
above) or a CNC machine (see Load below).
LOAD Uses a robot to insert a part into a CNC machine and
downloads the appropriate G-code to the machine if
required. The Load command is similar to the
Place command with the added feature that it
ensures the required G-code is downloaded..
UNLOAD Removes a part from a CNC machine. The Unload
command is similar to the Place command.
Comment Line NOP This line is ignored. It can be used for adding
comments or blank lines to the A-Plan.
User-Defined Process Process Executes the process as defined in the Machine
Name Process table. Each user-defined process that appears
in a Part Definition table for this product also
appears in the A-Plan table.

OpenCIM Programming
The following A-Plan commands shown in detail are representative of how to interpret the
other commands.
MAKE
Format MAKE <ttl qty> <initial qty> <subsqnt qty>
<priority type> <priority #>
Description Defines the beginning of a loop used to produce the quantity ordered for
each line in the Order table.
SUBPART Name of the product being ordered. This name is
made unique by a suffix which identifies the position
of this part in the Part Definition tree.
Target Sequential number that corresponds to a line number
in the Order table. This number is incremented by
one for each occurrence of a Make command in the
A-Plan table.
<ttl qty> Total number of products to be produced.
<initial qty> Number of parts produced in parallel when
production of this part first begins.
<subsqnt qty> Number of parts produced in parallel after the initial
quantity has been completed.
<priority Priority method used to determine which part order
type> gets produced first. Valid methods are:
P - Produce orders with the highest priority first.
D - Try to finish all parts by their Due Time.
B - Consider both priority and due time when
determining the sequence of production.
<priority #> Priority of this order (1 - 9). A priority of 1 is most
urgent, 9 is least urgent. When <priority type>
is set to either P or B, the CIM Manager uses
<priority #> to determine the sequence in
which to produce orders.
Example MAKE COVERED_BOX/1.1 1 1,1,1,P,1
Note See the NEXT command.

OpenCIM Programming
GET
Format GET <subpart> <storage location>
Description Reserves a part in a storage location that is needed to produce the current
order. The default storage location is the ASRS. Parts can also be stored in
a storage rack, a part feeder, or some other designated location. If no part
is available, a warning message appears on the CIM Manager screen and a
Wait status symbol on the Production screen.
<subpart> The subpart in a storage location that is
being reserved.
<storage location> The place in the CIM cell from where you
want to order the part. If this field is
omitted, the ASRS is assumed.
Example GET BOX ASRS1
Note See also STORE and RENAME.
You can view/edit a table of A-Plan commands that is created when you submit an order.
Parts that have a 1 in the # column can be produced in parallel (except for a part associated
with an ONFAIL process). The commands in this table are executed from top to bottom.
Processes that have a blank entry in their Subpart column operate on the last subpart listed
previously. For example, in the figure below, processes 3 and 4 operate on the BOX subpart
shown in line 2. Process 6 operates on COVER/1.1 shown in line 5.
Robot pick-and-place operations are not shown in the A-Plan table. The CIM Manager
implicitly performs these operations when it needs to move a part from one station location
to another.
Figure 11-11: A-Plan Table

You can track the current status of production by watching the Program View screen on the
CIM Manager PC. This screen shows the commands that the CIM Manager executes to
produce an order.

OpenCIM Programming
Figure 11-12: Program View Showing A-Plan Used to Produce an Order
The elements of the Program View screen are described in detail in Chapter 6, Operating
CIM Manager.

OpenCIM Programming
12
Inside OpenCIM
This chapter describes various OpenCIM administration procedures for the advanced user. It
includes the following sections
OpenCIM Loader: DDLoader.EXE, describes the OpenCIM
Loader that is used to start up all device drivers belonging to the
same workstation on each Station Manager PC.
OpenCIM Directory Structure, describes default OpenCIM
directory structure of the CIM folders and files that is automatically
created in the installation procedure.
OpenCIM Database Structure, displays lists of tables consisting of
the files contained in the OpenCIM database
Software Backup, describes the OpenCIM backup procedures.

Inside OpenCIM
OpenCIM Loader: DDLoader.EXE
The OpenCIM Loader automates the start-up of the Device Drivers under Windows. The
Loader runs on each workstation PC in order to automatically start up the Device Drivers on
these PCs:
OpenCIM Device Drivers Started by the Loader
Station Manager PCs Each device driver running on this PC
You can set up the programs you want the Loader to run in an INI file that you specify on
the Loader's command line. (In order to display the Path and Command Line columns of the
Loader, select Show All Columns from the File drop-down menu.) Clicking on the Loader's
icon on the Program Manager screen would thus start up all the programs listed in this INI
file. The Loader should be used to start up all device drivers belonging to the same
workstation on each Station Manager PC.
Figure 12-1: CIM Device Loader Sample

The name of this INI file typically corresponds to the station number as follows:
Workstation Naming Conventions
WS1.INI Settings for workstation No. 1.
WS2.INI Settings for Workstation No. 2

The Loader looks through the INI file for the section entitled [Loading] and runs the
programs (maximum eight) specified. Use a text editor to edit the command line for each
program in this INI file.
The following example of an INI file shows the command lines invoked by the Loader
[General]
CimSetupPath = ..\CIMCELL\SETUP\SETUP.CIM

[Loading]
Load1=..\BIN\BCRDRIVER.EXE BCRVD1.INI 13 /COM:2 /C
Load2=[default system drive (for example
C:)]\Intelitek\Scorbase\Bin\Scorbase.EXE /I=SCBSVD1.INI
/N=11
Loader Command Lines
Each device (or controller) that is connected to a Station Manager PC requires a separate
device driver running on that PC. It is possible to have a controller attached to a Station
Manager PC that supports multiple devices (e.g. a robot and a bar code reader attached to a
Scorbase controller). In this case, only one device driver is required (e.g. a Scorbase device
driver). In this section, the term device can also refer to a controller with multiple devices.
Inside OpenCIM
The list below shows the name of the program that corresponds to each OpenCIM device
driver:
ACL device driver: ACLDriver.EXE
CNC device driver: CNCDriver.EXE
Laser Scan Meter device driver: LSMDriver.EXE
ROBOTVISIONpro device driver: RVPDriver.EXE
PLC device driver: PLCDriver.EXE
ULS device driver ULSDriver.EXE
ViewFlex device driver ViewFlex.EXE
Scorbase for Controller-USB Device Driver Scorbase.EXE
Scorbase NXC100 and XtraDrive
Scorbase for Controller-USB PRO controller
Hydraulic device driver HYDDriver.exe
Pneumatic device driver PNEUDriver.exe
Process device driver ProcDriver.exe
BCR device driver BCRDriver.exe
The table below describes the command line switches you can specify when you invoke a
device driver or program module. These switches let you specify the device, data files, and
control mode that apply to a program.
All device drivers share the following command line format:
xxx.EXE IniFile DevID /COM:n [/Simulation]
(where xxx is the type of device driver).
IniFile The name of the initialization file containing parameter definitions
for this particular device. These parameter definitions override
global values set in the file OPENCIM.INI
DevID The unique ID number of the device as defined in the Setup
program. This number is used to identify the device when
communicating with the CIM Manager or with another CIM device
(e.g. a CNC machine being tended by this robot).
If more than one device is attached to a controller, you can specify
the ID of any one of these devices (e.g. the robot's ID in the case of
an ACL controller).
COM:n The RS232 port on the Station Manager PC that the device driver
uses to communicate with the device. Com ports 1 - 4 are supported.
Com parameters (baud rate, parity, etc.) can be assigned in the
initialization file IniFile, in the section for this device. For
example:
[CNCDriverDefinitions]
A port value of 0 (zero) indicates that the device driver is to operate
in Manual mode.
/Simulation This optional switch starts up the device driver in Simulation mode.
In this mode, the device driver emulates a robot by automatically

Inside OpenCIM
generating status messages in response to command messages.
You can invoke a device driver in any one of the following ways:
Use the OpenCIM Loader to automatically start up a set of device
drivers listed in the [Loading] section of an INI file.
In the Windows Program Manager, click on an icon which is defined
to run the device driver.
In the Windows Program Manager, select File, Run and enter the
device driver command line.

Inside OpenCIM
OpenCIM Directory Structure
Each PC on which the OpenCIM software has been installed has the same directory
structures.
The OpenCIM software and the projects files are installed in separate locations. The file
structures of the two are detailed below.
Installation Directory
The CIM software is installed in the programs files directory (for example: [default system
drive (for example C:)]\Program Files\Intelitek\OpenCIM\).
Some of the subdirectories are described below:
Subdirectory Description
Bin OpenCIM software files
Books OpenCIM software book
Sources
QueAlgDef Queue algorithm source dll to which you can add your
own algorithms for the machine queue.
RW Documentation on how to develop custom parts.
Converter Application for converting a graphic module from
Autocad or 3D studio to RWX.
Documentation Documentation detailing how to work with the graphic
modules.
Figure 12-2: OpenCIM Installation

Directory Structure
Projects Directory
CIM projects are installed in the public user directory:
Windows XP: [default system drive (for example C:)]\Documents
and Settings\All Users\Documents\Intelitek\OpenCIM\
C:)]\Users\Public\Documents\Intelitek\OpenCIM\
This directory contains the projects folders.

Inside OpenCIM
Project Folder: Contains all project folders and a lib directory which includes preconfigured
setup files for common machines, robots and stations.
WorkStations Folders: In every project folder you can find subfolders with data that is
relevant only to a specific station (e.g. WS1, WS2). The project folders can be located on the
CIM Manager PC (if you want to centralize the system data) or on that station PC. It is
recommended to use the first structure, where the data is kept in a single location as it
facilitates backup.
The figure below shows the OpenCIM projects directory structure (path listing) before any
OpenCIM system is created using the Virtual CIM Setup.
Figure 12-3: OpenCIM Projects Directory Structure

CIM CUSTOM_PARTS: contains all the RWX files for parts provided by Intelitek. For
information on modifying these parts and creating new ones, refer to Chapter 7: CIM
Manager Utility Programs.
For every cell created by the Virtual CIM Setup, a subdirectory, which contains the
following subdirectories, is created:
Subdirectory Description
DATA Contains data files that change during the normal operation of the CIM.
DOC Contains all documentation relevant to this particular system.
LOG Contains a log of the system.
SETUP Contains all the files that change when setting up the CIM cell.
WS0 Workstation Manager.
WSn Contains all data files that are unique to this station.
VC2_WM.DBF OpenCIM network messages file.
CIMCELL.INI These files contain graphic information of the cell.
VC2.INI
CIMCELL.O2B
CIMCELL.O2C
CIMCELL.O2P
The WSn subdirectories represent each of the workstations in the CIM cell.
The subdirectory is created in the CIM Manager for each specific WSn. and is then shared
via the network with the Station Manager. A subdirectory is created for each machine at that
workstation.
A system with three workstations (WS1, WS2, WS3) may be set up as follows, for example:

Inside OpenCIM
The WS1 subdirectory contains all INI files and DBF files that are
unique to workstation #1. ROBOT 1 contains all of the robot
programs specific to workstation #1.
unique to workstation #2. ROBOT 2 contains all of the robot
programs specific to workstation #2. GCODE contains all the G-
code programs necessary for the CNC machine.
unique to workstation #3.
The table below lists the files found in a typical OpenCIM system, grouped by subdirectory.
The subdirectory generically called CIMCELL represents a typical CIM cell.
File Type Description
Projects Directory\LIB\ACL Subdirectory containing a library of generic ACL source code,
utility programs, and parameter files.
CIMSYS.DMC Source code of standard ACL system programs for a single robot
attached to an ACL controller.
CIMSYSM.DMC Source code of standard ACL system programs for multiple robots
attached to the same ACL controller.
Projects
Directory\LIB\ACL\AT
S
DOWNLOAD.EXE ACLoff-line downloader utility program that sends DNL files to an
ACL controller.
SEND.EXE Utility program to send a command to an ACL controller.
TERM_ACL.EXE ATS terminal emulation program used to interact with an ACL
controller.
SETUP.DIR A data file used by the TERM_ACL program.
ASRSB.PRB ACL parameter files.
ASRSSQ.PRB
BELT.PRB
LSB100CM.PRB
LSB150CM.PRB
LSB20.PRB
NOCONECG.PRB
NOCONECT.PRB
ROTARY_B.PRB
SERVOG_C.PRB
XYTAB.PRB
SCC_BELT.PRB
SETUP.PAR Location of the Robot parameters.
ATS.BAT Batch file to load the TERM_ACL.EXE.
TERM.MAC
ONOFF.CBU On/Off program for the controller.
PAR.CBU File containing parameters for the controller.
PAR14.CBU File containing parameters for Robot ER 14.
PARMK2.CBU File containing parameters for Robot MK2.

Inside OpenCIM
BIN Subdirectory containing OpenCIM program files (EXE, DLL, HLP,
ICO, TRK, VBX).
C4DLL.DLL Object code files containing a shared library of Windows programs.
DBCREATER.DLL
QueAlgDef.dll Machine queue algorithms Dll
VBC4DLL.DLL
OpenCIM_Ver4.5.chm Help file
ACLDRIVER.EXE The ACL device driver.
APLAN.EXE The A-Plan program.
BCRDriver.exe The bar-code device driver

CHECKCOMMUNICATION. Utility program for testing TCP/IP communications.
EXE
CIMREPORT.EXE Report Generator program
CIMSAF.EXE OpenCIM safety device driver
CIMSETUP.EXE Virtual CIM Setup program
CIMSIMUL.EXE Graphic Display Program Loader
CNCDRIVER.EXE CNC device driver
DBTOOL.EXE Edits database files
DDLOADER.EXE Loader program for device drivers
HYDDriver.exe Hydraulic device driver
LSMDRIVER.EXE Laser Scan Meter device driver
MACHINEDEFINITION. Machine Definition module
EXE
MANAGER.EXE CIM Manager module
MRP.EXE MRP module
Optimization.exe Optimization Utility
PARTDEFINITION.EXE Part Definition module
Performance.exe Performance Utility
PLCDRIVER.EXE PLC device driver
PNEUDriver.exe Pneumatic device driver
ProcDriver.exe Process device driver
ProjectManager.exe Project Manager Program
RFIDDriver.exe RFID Device Driver
RVPDRIVER.EXE ROBOTVISIONPro Device Driver
SCHEDULER.EXE Scheduler Module
SCRIPTER.EXE Activates Graphic Display commands
STORAGEMANAGER.EXE Storage manager module
ULSDRIVER.EXE Laser Engraver Device Driver
CIMCELL Generic name for a subdirectory containing all data for one
particular CIM cell, as created by the Virtual CIM Setup.

Inside OpenCIM
CIMCELL Subdirectory containing data files used by the OpenCIM system.
/ DATA (*.DBF is a file in dBASE format).
ORDER.CFG Internal configuration parameters used by the MRP.
APLAN.DBF A-Plan commands generated by last order submitted.
BACK.DBF The REF.BAT batch file uses this data file to restore
STORAGE.DBF.
CSTORDER.DBF Details of the customer order.
CUSTOMER.DBF List of customers.
CIMREP.DBF Report format specifications.
LEAFPART.DBF Internal information used by the CIM Manager to display active
production operations in Leaf View.
MACHINE.DBF List of machines as defined in the Machine Definition.
OPT_MQUEUE.DBF List of which algorithm to use for each machine queue.
ORDER.DBF Records that appear in the Order table.
PART_DEF.DBF Records that appear on the Part Definition screen.
PART_PRC.DBF Records that appear in the Part Process table.
PERF_SUMM.DBF System performance summary.

PROCESS.DBF Records that appear in the Machine Process table in the Machine
Definition module.
Performance.dbf Machine performance summary.
REPORT.DBF Records that appear in the Report table.
PROCESS.DBF Machine process sumarry.
SCHEDULER.BDF Information used by the scheduler.
PURCHASE.DBF List of item parts for purchase.
STORAGE.DBF Contents of all storage devices.
SCHEDULER.DBF Machine task schedule summary.
SUPPLIER.DBF List of Suppliers.
TEMPLATE.DBF.DBF Conveyor template definitions as assigned in the Storage Definition
module.
ANALYSIS.RPT Listing of files for the Report Generator. Each file is named
APLAN.RPT according to the report and/or application it applies to.
ASRS.RPT
ASRSSUM.rpt
LOCATION.RPT
MACHINE.RPT
OPTIMIZATION.rpt
ORDER.RPT
PART.RPT
partprocess.rpt
performance.rpt
PROCESS.RPT
PURCHASE.RPT
PurchaseNew.rpt
Inside OpenCIM
SUBPART.RPT
MACH_MAC.CDX dBASE index files automatically generated by the programs which
P_DEF_AP.CDX update the associated DBF files.
PROC_AP.CDX
PDEF_PAR.CDX
PROC_PAR.CDX
P_DEF_OR.CDX
MACH4TAG.CDX
P_PRC_AP.CDX
ORDER_AP.CDX
PART4TAG.CDX
PARTD_AS.CDX
STR_TEMPLATE.CDX
CIMCELL Subdirectory containing LOG files for the system.
/ LOG
CIMCELL Subdirectory containing installation and configuration related files.
/ SETUP
MAP.INI Data file that associates PC network file names with workstation
numbers. Also used to assign multiple devices to a single device
driver.
SETUP.CIM Configuration data file; contains all devices and their associated
parameters.
DEVICE.DMC Assignment of device names to ACL program numbers.
OPENCIM.INI Default device driver parameters.
FDR1.INI File detailing the files used by each storage device.
RACK1.INI File containing the configuration of the rack.
PNEUST1FDR1 File containing the configuration of the pneumatic station.
CONPALET.INI File containing the minimum number of empty pallets running in the
conveyor.
CIMCELL Subdirectory containing files for the CIM Manager PC.
/ WS0
CIM.LOG OpenCIM network messages file for this station.
CIM.PRT File containing a listing of all messages (LOG file).
WS0.INI Parameters passed into the CIM Manager at initialization time.
CIM.PNP Pick-and-place file.
CIM.LOG File containing the leaf view (LOG file).
ERROR.LOG Error graphic file
OLMT.TXT List of Messages sent to Simulation (Log file).
CIMCELL Subdirectory containing files for a typical workstation.
/ WSn
ACLVD1.INI ACL Virtual driver.
VC2_QC.INI Format settings for quality control report.
BCRVD1.INI BarCode Virtual driver.
SCBSVD1.INI Scorbase Virtual driver

Inside OpenCIM
PNEUVD1.INI Pneumatic Station Virtual driver
$ACL_011.PRT File containing ACL device driver protocol.
CNCVD1.INI CNC Virtual driver.
ULSVD1.INI ULS Virtual driver
HYDVD1.INI Hydraulic Station Virtual driver
VFVD1.INI ViewFlex Virtual driver
PROCVD1.INI Process Virtual driver
$LSM_009.PRT File containing LSM device driver protocol.
LSMVD1.INI LSM Virtual device driver INI file.
$PLC_001.PRT File containing PLC device driver protocol.
PLCVD1.INI PLC virtual device driver.
WS1.INI Typically used to pass command line parameters to the Loader
program used to start each device driver at this station in Real mode.
ACL_011.PNP Pick-and-place file.
Every machine, robot or station directory in a workstation contains a number of preconfigured setup
files.
The following is an example of a robot directory which contains files for the Robots in the stations.
CIMCELL Subdirectory containing files for the ACL controller at Station n.
/ WSn
/ ROBOTn
REPORT.DLD Log file showing the commands executed during the last ACL
download (see the ACLoff-line manual).
WS2.DNL Listing of all the download robot programs for this station.
TRASH1.DNL
BFFR1.DNL
RDR1.DNL
RACK1.DNL
CNV1.DNL
EPILOG1.DNL
PROLOG1.DNL
FDR1.DNL
ASMBUF.DNL
ASRS.DNL
RVPCOM2V.QCL Listing of all download Quality Control robot programs.

RVPCOMOV.QCL
RVPCOM1V.QCL
RVPCOM.QCL
SETUP.DIR Data file used by the TERM_ACL program.
CIMCELL Subdirectory containing files for controllers operated by Scorbase

/ WSn software
/ ROBOTn
STN.WS
Inside OpenCIM
STN.SBP
STN.PNT
LIB Subdirectory containing preconfigured setup files for common
machines, ACL programs, etc. (library of ACL programs).
Located in the projects directory
LIB Subdirectory containing a library of unique ACL source code, utility
/ ACL programs, and parameter files.
Projects Subdirectory containing a library of generic ACL source code,
Directory\LIB\ACL utility programs, and parameter files.
CIMSYS.DMC Source code of standard ACL system programs for a single robot
attached to an ACL controller.
CIMSYSM.DMC Source code of standard ACL system programs for multiple robots
attached to the same ACL controller.
Projects
Directory\LIB\ACL\AT
S
DOWNLOAD.EXE ACLoff-line downloader utility program that sends DNL files to an
ACL controller.
SEND.EXE Utility program to send a command to an ACL controller.
TERM_ACL.EXE ATS terminal emulation program used to interact with an ACL
controller.
SETUP.DIR A data file used by the TERM_ACL program.
ASRSB.PRB ACL parameter files.
ASRSSQ.PRB
BELT.PRB
LSB100CM.PRB
LSB150CM.PRB
LSB20.PRB
NOCONECG.PRB
NOCONECT.PRB
ROTARY_B.PRB
SERVOG_C.PRB
XYTAB.PRB
SCC_BELT.PRB
SETUP.PAR Location of the Robot parameters.
ATS.BAT Batch file to load the TERM_ACL.EXE.
TERM.MAC
ONOFF.CBU On/Off program for the controller.
PAR.CBU File containing parameters for the controller.
PAR9.CBU File containing parameters for Robot ER IX.
PARMK2.CBU File containing parameters for Robot MK2.
LIB/ Hydraulic Subdirectory containing hydraulic station files.
Load.pgm
Press.pgm
Inside OpenCIM
Unload.pgm
LIB/ QC Subdirectory containing examples of Quality Control INI files.
VC2_QC.INI
LIB/ SCR Subdirectory containing all the CNC script and BATCH file
examples.
SCRLAB.DBF
SCRILAB.DBF
SCRTIL.DBF
SCRSITIL.DBF
SCRPRJ.DBF
VC2_WM.EXP
CNC_L.LAB
EXAMPLE.DBF
CNC_L.BAT
CNC_SCR.DBF
CNCSCRSI.DBF
LIB/ ViewFlex Subdirectory containing all the ViewFlex Scripts
CHECK_V.bas
FIND_4_PINS.bas
FIND_4_SCREWS.bas
Lower_Left_Pin.mod
Lower_Left_Screw.mod
Lower_Right_Pin.mod
Lower_Right_Screw.mod
Upper_Left.mod
Upper_Left_Pin.mod
Upper_Left_Screw.mod
Upper_Right_Pin.mod
LIB/ Vuniq40 Subdirectory containing required files to work with with Vuniq.
MAP.INI
The setup file MAP.INI performs the following functions:
Contains the TCP/IP configuration of the manager and all device
drivers in an OpenCIM cell. This information is required by each
OpenCIM in order to enable communication with other OpenCIM
entities.
Allows two or more devices to use the same device driver to send
and receive messages
A typical MAP.INI has the following format:
[Redirect]
53=51
Inside OpenCIM
23=21
24=21
[COMMMANAGER]
RemoteIP=200.1.1.1
RemotePort=700
[COMMACL11]
RemoteIP=200.1.1.1
RemotePort=711
[COMMLSM13]
RemoteIP=200.1.1.1
RemotePort=713
[COMMACL21]
RemoteIP=200.1.1.1
RemotePort=721
[COMMACL24]
RemoteIP=200.1.1.1
RemotePort=724
When a device driver starts, it must access MAP.INI in order to be able to communicate with
other device drivers and the CIM Manager. On each Station Manager PC the file path to
MAP.INI is contained in the parameter variable CimMapPath in the [Networking]
section of the INI file for this station.
To guarantee proper operation of OpenCIM, be sure that the file MAP.INI is accessible to all
device drivers. To be sure that the MAP.INI file is accessible, do the following:
Note
Open any device driver
Check if the MAP.INI file is updated by editing the TCP/IP configurations of the DD
opened
You can use any ASCII text editor (e.g. Windows Notepad) to modify MAP.INI. The two
types of entries in this file are described below.
Since only one device can be assigned to a device driver on a command line, an ID entry in
MAP.INI is used to assign other devices to this device driver. For example, a bar code reader
(device 13) and a robot (device 11) may be connected to the same ACL controller and thus
share the same ACL device driver for passing OpenCIM messages. The following command
line assigns the robot to the ACL device driver:
ACLDriver.EXE ACLVD1.INI 11,13 /COM:2
The following MAP.INI entry allows the bar code reader to share the use of this device
driver:
[REDIRECT]
13=11
13 A device that is sharing the use of a device driver.
11 The primary device that is assigned to a device driver on the command line
that invokes the device driver.

Inside OpenCIM
SETUP.CIM
SETUP.CIM is an ASCII file which defines all devices found in the OpenCIM system. The
file is located in the path Projects Directory\CIMCELL\SETUP. The fields in this
file are separated by a space.
The SETUP.CIM file for the CIMLAB4 Virtual CIM is shown below.
5
51 1 ER5P ROBOT1 R 1 0 0 0 0 0
52 2 ER9 ROBOT2 R 1 0 0 0 0 0
53 3 ER5P ROBOT3 R 1 0 0 0 0 0
54 4 ER7 ROBOT4 R 1 0 0 0 0 0
0 0 PLANE PLANE 0. 0. 0.
1 2 CNV1 CNV1 C 4 0 0 0 4 ROBOT1 0 ROBOT2 0 ROBOT3 0 ROBOT4 0 0
55 4 ERXY XYJIG J 1 0 0 0 1 ROBOT4 0 0
2 1 RNDAS RNDAS1 A 54 0 0 0 1 ROBOT1 0 0
3 1 READER RDR1 Y 1 0 0 0 1 ROBOT1 0 0
4 2 MILL_S MILL1 M 1 0 0 0 1 ROBOT2 0 0
5 2 M2AS BFFR1 B 2 0 0 0 1 ROBOT2 0 0
6 2 M2AS BFFR2 B 2 0 0 0 1 ROBOT2 0 0
7 3 LATH_S LATHE1 M 1 0 0 0 1 ROBOT3 0 0
8 3 M2AS BFFR3 B 2 0 0 0 1 ROBOT3 0 0
9 4 M2AS BFFR4 B 2 0 0 0 1 ROBOT4 0 0
10 4 FEEDER FDR1 F 1 201 0 20 1 ROBOT4 0 0
11 4 RACK RACK1 K 9 101 0 0 1 ROBOT4 0 0
12 4 RACK RACK2 K 2 102 0 0 1 ROBOT4 0 0
13 4 TRASH TRASH1 X 1 0 0 0 1 ROBOT4 0 0
14 4 JIG JIG1 J 1 0 0 0 1 ROBOT4 0 0
17 4 VISION VSN1 V 1 0 0 0 1 XYJIG 0 0
16 4 SCREWD SDRV1 D 1 0 0 0 1 XYJIG 0 0
51 1 ER5P ROBOT1 R 1 0 0 0 0 0
52 2 ER9 ROBOT2 R 1 0 0 0 0 0
53 3 ER5P ROBOT3 R 1 0 0 0 0 0
54 4 ER7 ROBOT4 R 1 0 0 0 0 0
60 0 SPARE CONPALET O 16 1 0 0 0 0

Inside OpenCIM
Fld# Field Name Type # Width Remarks
1 Device ( Object/Location ) ID Numeric 3
(Do not skip numbers, make all IDs sequential)
2 Station Number Numeric 2
3 Physical Name (for graphic display) Character 20
4 Logical Name Character 20
5 Type: Character 1
A: ASRS M: Machine
B: Buffer O: Conpallet
C: Conveyor P: Part
D: Device (e.g. Q: Quality Control
screwdriver) R: Robot
F: Feeder
S: User Defined
H: Reserved
U: Undefined
I: Station
V: Vision
J: Jig
X: Trash
K: Rack
Y: Barcode or RFID
L: Laser Scan Meter
Z: AGV
6 Capacity Numeric 2
7 Subtype (type of objects it can hold) or Numeric 3
Connectivity (used with Feeder, Rack, Conpallet
and Buffer)
8 Location ID (for graphic display) Numeric 3
9 Location Position (for graphic display) Numeric 2
10 Number of Robots Numeric 2
(that can access this device)
11 Robot's Name Character 20 Multiple field
12 Robot's Position Numeric 2 Multiple field
13 Steady Flag Logical 1

Inside OpenCIM
The following is an example of a SETUP.CIM file.
1
11 1 SQRAS SQRAS1 R 1 0 0 0 0 0
211 1 ASRS ASRS1 A 72 0 0 0 1 SQRAS1 0 0
21 2 ER9 ROBOT5 R 1 0 0 0 0 0
31 3 MK3 ROBOT3 R 1 0 0 0 0 0
41 4 ER14 ROBOT4 R 1 0 0 0 0 0
0 0 PLANE PLANE 0. 0. 0.
1 1 CNV1 CNV1 C 4 0 0 0 4 SQRAS1 0 ROBOT5 0 ROBOT3 0 ROBOT4 0 0
12 1 READER RDR1 Y 1 0 0 0 1 SQRAS1 0 0
24 2 PCMILL PCMILL1 M 1 0 0 0 1 ROBOT5 0 0
23 2 PCTURN PCTURN1 M 1 0 0 0 1 ROBOT5 0 0
33 3 WELDST WELDST1 D 1 0 0 0 1 ROBOT3 0 0
49 4 CMM CMM1 Q 1 0 0 0 1 ROBOT4 0 0
47 4 VISION VSN1 V 1 0 0 0 1 ROBOT4 0 0
44 4 RACK RACK1 K 1 101 0 0 1 ROBOT4 0 0
45 4 RACK RACK2 K 1 102 0 0 1 ROBOT4 0 0
43 4 JIG JIG1 J 1 0 0 0 1 ROBOT4 0 0
48 4 TRASH TRASH1 X 1 0 0 0 1 ROBOT4 0 0
22 2 M2AS BFFR1 B 2 0 0 0 1 ROBOT5 0 0
32 3 M2AS BFFR2 B 2 0 0 0 1 ROBOT3 0 0
42 4 M2AS BFFR3 B 2 0 0 0 1 ROBOT4 0 0
46 4 FEEDER FDR1 F 1 103 0 0 1 ROBOT4 0 0

Inside OpenCIM
DEVICE.DMC
The DEVICE.DMC file in the SETUP directory defines numbers for the ACL logical name
of every device in the system.
The DEVICE.DMC file for the CIMLAB4 Virtual CIM is shown below.
#IFNDEF _DEVICE_DMC
#DEFINE _DEVICE_DMC
#DEFINE CNV1 001
#DEFINE RNDAS1 002
#DEFINE BFFR1 005
#DEFINE BFFR2 006
#DEFINE BFFR3 008
#DEFINE BFFR4 009
#DEFINE FDR1 010
#DEFINE RACK1 011
#DEFINE RACK2 012
#DEFINE TRASH1 013
#DEFINE ROBOT1 051
#DEFINE ROBOT2 052
#DEFINE ROBOT3 053
#DEFINE ROBOT4 054
#DEFINE ROBOT5 055
#DEFINE MILL1 004
#DEFINE LATHE1 007
#DEFINE JIG1 014
#DEFINE SDRV1 016
#DEFINE VSN1 015
#DEFINE RDR1 003
#ENDIF
For an explanation of this file and how to edit it, refer to Writing ACL Source Code in
Chapter 11, OpenCIM Programming.

Inside OpenCIM
INI Files
OpenCIM uses a set of INI files to set configuration parameters for the following programs:
Each OpenCIM device driver
The CIM Manager
The OpenCIM Loader
The Storage Definition module
OpenCIM parameter settings for the above programs are stored in a set of text files: *.INI.
These files use the same structure as standard Windows INI files such as WIN.INI. These
programs read their respective INI files at initialization time. If you make a change to a
programs INI file after it has started, you must end the program and restart it for the change
to take effect.
Default values for all devices are stored in the file OPENCIM.INI. Settings for individual
devices can be made in a local INI file which is specified on the device driver loaders
command line. If the same parameter appears in both OPENCIM.INI and a device driver's
local INI file, the local setting takes precedence. All parameters must appear in either
OPENCIM.INI or in a local INI file.
The (OPENCIM32\CIMLAB4\SETUP\) OPENCIM.INI file for the CIMLAB4 setup is
shown below.
[General]
CimSetupPath=..\SETUP\SETUP.CIM
CimSetupDir=..\SETUP
CimLibDir=..\LIB
CimDataDir=..\DATA
CimWorkDir=..\data
CimReportDir=..\DATA
[Networking]
CimMapPath=..\SETUP\MAP.INI
Timer=300
AttemptsCount=3
PassCount=3
OffDelay=3
EchoFilter=1124
[Simulation]
PCPLC=20,7,15
[ASRS1]
NumberOfRows=6
NumberOfCols=6
NumberOfGrids=2
FirstGridWithMinIndex=Bottom
LocationMinIndexGrid=LeftBottom
DirectionIncIndexGrid=Right
[WndStatus]
PROGDEF=0
ORDERDER=0
STRGDEF=0
DEVICEDEF=0
LOGDEF=0
PALLETEDEF=0
LEAFDEF=0
EVENTDEF=0
MANAGERDEF=0
HYSTORYDEF=0
[CIMMODES]
TRACKINGMODE=0
Inside OpenCIM
UPDATEDURATION=0
SENDTOGRAPH=0
SIMULATION=1
CIMSPEED=1
[DDFileName]
CNV1=..\CIMLAB4\WS1\PLCVD1.INI
SQRAS1=..\CIMLAB4\WS1\ACLVD1.INI
RDR1=..\CIMLAB4\WS1\LSMVD1.INI
ROBOT5=..\CIMLAB4\WS2\ACLVD5.INI
PCTURN1=..\CIMLAB4\WS2\CNCVD1.INI
PCMILL1=..\CIMLAB4\WS2\ CNCVD2.INI
VSN1=..\CIMLAB4\WS4\RVPVD1.INI
CMM1=..\CIMLAB4\WS4\LSMVD2.INI
You can use some combination of the parameter file strategies listed below when deciding
how to organize INI files for your system:
Put all default parameter settings in OPENCIM.INI. Then write a separate INI file for each
device driver that contains only those parameters that deviate from the default.
Have a separate INI file for each device driver containing all the parameters for that device.
Use OPENCIM.INI only for global parameters.
Have a separate INI file for each Station Manager PC (e.g. WS1.INI) which contains the
parameters for all devices at that station. These files would also contain the command lines
used by the Loader to start each device driver at a station. Use OPENCIM.INI only for
global parameters.
To set up or edit an INI file, use a text editor (e.g. Windows Notepad) that can save files in
ASCII format. The file is divided into sections with the title of each section enclosed in
brackets, for example [Networking]. A program searches for the sections that apply to it and
reads the associated parameter settings. Keep the following considerations in mind when
editing an INI file:
Only lines that begin with valid parameter names are read (i.e. only parameters that belong in
that section), all other lines are ignored. If you misspell a parameter name, it will be ignored.
A leading space at the beginning of a line will cause that line to be ignored.
Do not insert the same parameter more than once in a section (there is no guarantee as to
which value will be used).
You can insert blank lines in an INI file to group related parameters and to set off sections.

Inside OpenCIM
You can create a comment line by inserting an extra character at the beginning of a line (by
convention the semicolon, ;). For example, if you want to try a new text color but also keep
the original value for reference, you could do the following:
;MainWindowTextColors = 0,255,0
MainWindowTextColors = 0,255,255
The table below lists all OpenCIM parameters that you can set. Note that some of the values
in the table are internal system parameters which should only be changed under the direction
of Intelitek technical support. The table is divided into the following sections:
INI Parameter Description
Default Settings (OPENCIM.INI)

[General] The parameters in this section define the
OpenCIM directory structure on the central
server PC.
CimLibDir=..\LIB Location of the original OpenCIM data and
program files. These data files can be copied to
the SETUP directory to restore the system to
its original state.
CimDataDir = ..\DATA Location of data files which define the
OpenCIM configuration (e.g. machine
processes, part definitions, etc.).
CimWorkDir = ..\DATA Location of data files, including log files,
which are updated during OpenCIM
production.
CimReportDir = ..\DATA Location of report output. Other software
applications can interface here to pick up
OpenCIM production data.
[Networking]
CimMapPath = ..\SETUP\MAP.INI The location of the OpenCIM map file which
contains:
The name of all workstation PCs.
A list of all devices which share the use of
a device driver (e.g. a robot, and an
automatic screwdriver all connected to the
same ACL controller).
Timer = 1000 The frequency at which a program checks its
mailslot for messages to transmit or receive.
The CIM Manager must check its mailslot
more frequently than the programs with which
it communicates (device drivers or Storage
Definition module).
CIM Manager: 200 - 600 ms
Device drivers: 400 - 1000 ms
Reserved for Intelitek technical support use
only.

Inside OpenCIM
INI Parameter Description
PassCount = 3 Number of Timer intervals to wait before a
retry is sent. For example:
Timer = 1000, PassCount = 3
delay before retry is 3000 ms
only.
OffDelay = 3 Number of milliseconds a device driver waits
for confirmation from the CIM Manager that it
has received a shutdown notification message.
A value of 0 (zero) causes the device driver not
to send a shutdown message.
ASRS Device Driver Settings
[Structure]
NumberOfRow = 6
NumberOfCols = 6
NumberOfGrids = 2
FirstGridWithMinIndex = Bottom
LocationMinIndexGrid = LeftUp
DirectionIncIndexGrid = Right

Inside OpenCIM
ACL Device Driver Settings
[General]
CimSetupPath =..\CIMCELL\SETUP\SETUP.CIM Tells the device driver where to find the

following important OpenCIM setup files:
OPENCIM.INI: Contains default
parameter settings for all device drivers.
The file OPENCIM.INI must appear in the
same directory as the setup file named in
this setting.
SETUP.CIM: Lists all physical devices
and their IDs. The name SETUP.CIM is
the default name for this file.
This parameter setting must appear in each
local INI file. It is not needed in
OPENCIM.INI.
[ACLDriverDefinitions]
ACLDriverPromptNum = 3 Number of times the device driver sends a
query to an ACL controller to invoke the
controller's command prompt, ">". Reserved
for Intelitek technical support use only.
BaudRate = 9600 These are the standard RS232 settings for
Parity = None
DataBits = 8
communicating with an ACL controller. They
StopBits = 1 should not be changed since they match the
XonXoff = Yes fixed settings in the controller.
MainWindowBkgndColors = 0,0,0 MainWindowBkgndColors = 0,0,0
Color settings for the background and text
colors in the device driver's Status window.
When a Station Manager PC is running several
device drivers simultaneously, these
parameters allow you to set each one to a
different color in order to distinguish between
them.
The three numbers represent a color using the
RGB color scheme (Red, Green, Blue). Values
range from 0255. A 0 (zero) indicates the
absence of red, green, or blue, respectively, and
255 signifies a primary color at full intensity.
For example:
Green =0,255,0
White = 255,255,255
Black = 0,0,0
Do not set the text color to the same value as
the background color. This combination would
cause the text to become invisible.

Inside OpenCIM
CNC Device Driver Settings
[General]
CimSetupPath= ..\CIMCELL\SETUP\SETUP.CIM See this parameter in the ACL section above.

CNCScriptFilePath = CNC_SCR.DBF These files contain the CNC script programs
CNCScriptDebugFilePath = CNC_SCRS.DBF which appear in the CNC Command List on
the Control Panel.
This first parameter specifies a file that is used
when the CNC device driver is operating in
Real Mode. The second parameter is an
alternate file used when the device driver is
operating in Simulation or Manual mode.
The file name is mandatory. If no path is
specified, the current working directory is used
as defined by the device driver's /C command
line switch.
MainWindowBkgndColors = 0,0,0 See these parameters in the ACL section above.
; --- CNC Variables ---
V1 = ACL21 Parameter variables used by CNC script
V2 =
V3 =
programs. These variables are used to write
V4 = portable CNC script programs. For further
V5 = information, see CNC Device Driver in
V6 = Chapter 8.

V16 =
BV0 = 0 These 8-bit values, which range from 0-255,
BV1 = 0
are assumed to be the initial state of the control
lines of a CNC machine when the system is
turned on.
PORT0 = 0x500 I/O port addresses on a Station Manager PC
PORT1 = 0X501
that are mapped to the status and control lines
of a CNC machine using a special interface
card. These values should match the jumper
settings on the I/O card.
CNCDriverDebuggerTimer = 100 Refresh interval (in milliseconds) for display of
input port values on the CNC Control Panel.
only.
CNCDriverTimer = 10 This is an internal timer (in milliseconds) used
during communications.
only.
CNCIdleProcTimer = 10 Polling interval (in milliseconds) for checking
the alarm status of a CNC machine.
only.

Inside OpenCIM
CNCIdle = CNCIDLE(port0, "00000010") This setting checks for an alarm condition on
the specified input port. If the value of the
input port matches this mask, the CNC device
driver sends the following alarm message to
the CIM Manager:
WM_CIMDDE_CNCERROR with the error
value = CNCALARM
BaudRate = 9600 RS232 parameters used by the CNC device
Parity = None
DataBits = 8
driver when it downloads G-code to a CNC
StopBits = 1 machine. You must set these parameters to
XonXoff = No match the RS232 settings on the CNC
machine.
Loader =Project directory Include the Loader parameter when you want
\WSN\taskload.bat
TaskLoadedMark = TASK.CNC to use your own program to download G-code
to a CNC machine (instead of using the device
driver's built-in downloader).
The Loader file name must be a batch file.
The last command in this file should create the
flag file specified in TaskLoadedMark. This
flag file signals that the download is complete.
The device driver automatically deletes this
flag file each time it invokes the Loader
batch file.
LSM Device Driver Settings
[General]
CimSetupPath== ..\CIMCELL\SETUP\SETUP.CIM See this parameter in the ACL section above.

[LSMDriverDefinitions]
QCReport = No Enables/disables creation of a log file for
capturing results from this quality control
device. If set to No, all other QC report
parameters below are ignored.
QCReportTemplateFile = VC2_QC.INI Name (including path) of the file that defines
the format of the quality control log file.
QCReportFileName = Name (including path) of the quality control
log file itself.
QCReportFileMarker = A flag file (including path) which indicates that
the quality control log file has been updated. A
user application can delete this flag file after
processing the log file. The next time the flag
file appears, the application knows that there is
new log file data to process.
QCReportFileDeleteOnStart = This switch controls whether a new quality
control log file will be created each time this
device driver starts up. If Yes, the previous log
file is deleted. If No, results are appended to
the existing log file.

Inside OpenCIM
SimulationFailPercent = 20 When the device driver is operating in
simulation mode, this value determines what
percentage of the simulated quality control
tests are randomly reported as failures. This
setting provides the default value that appears
in the Fail % box on the QC Control Panel. The
range is 0100 (0 = test always passes,
100 = test always fails).
BaudRate=9600 RS232 parameters used by the QC device
Parity=None
DataBits=8
driver when it communicates with the
StopBits=1 controller for the quality control device. You
XonXoff=No must set these parameters to match the RS232
settings on the devices controller.
MainWindowBkgndColors=40,150,100 See these parameters in the ACL section above.
RFID Device Driver Settings

[General] See these parameters in the ACL section above.
CimSetupPath=..\CIMCELL\SETUP\SETUP.CIM
[Networking] Contains the TCP/IP configuration of the
CimMapPath=..\CIMCELL\SETUP\MAP.INI
manager and all device drivers in an OpenCIM
cell.
[RFIDDriverDefinitions] RS232 parameters used by the RFID device
BaudRate=9600
driver for communication with the RFID
Parity=None
reader.
DataBits=8
StopBits=1
XonXoff=No
ROBOTVISIONpro Device Driver Settings

[General]
CimSetupPath== ..\CIMCELL\SETUP\SETUP.CIM See this parameter in the ACL section above.
[RVPDriverDefinitions]
Frame=1 Frame number as defined on the Frame
Definition screen in the Setup menu of the
ROBOTVISIONpro software. See the
ROBOTVISIONpro documentation for details.
Snap=No For older versions (prior to v2.3) of the
ROBOTVISIONpro software, set this value to
Yes. For v2.3 and later, set it to No. For best
results, use only v2.3 and later.
BaudRate=9600 RS232 parameters used by the QC device
Parity=None
DataBits=8
driver when it communicates with the
StopBits=1 controller for the quality control device. You
XonXoff=No must set these parameters to match the RS232
settings on the device's controller.
MainWindowBkgndColors=150,150,150 See these parameters in the ACL section above.
SimulationFailPercent=50 See this parameter in the Laser Scan Meter
section above.

Inside OpenCIM
QCReport=Yes See these parameters in the Laser Scan Meter
QCReportTemplateFile=VC2_QC.INI
QCReportFileName=
section above.
QCReportFileMarker=
QCReportFileDeleteOnStart=
ViewFlex Device Driver Settings

[General]
ScriptPath= project
directory\cimcell\ws3

Inside OpenCIM
ULS Device Driver Settings
[General]
CimSetupPath=..\CIMCELL\SETUP\SETUP.CIM
[Networking]
CimMapPath=..\CIMCELL\SETUP\MAP.INI
BaudRate = 9600 RS232 parameters used by the CNC device
Parity = None
DataBits = 8
driver when it downloads G-code to a CNC
StopBits = 1 machine. You must set these parameters to
XonXoff = No match the RS232 settings on the CNC
machine.
; --- CNC Variables ---
V1 = ACL71 Parameter variables used by CNC script
V2 =
V3 =
programs. These variables are used to write
V4 = portable CNC script programs. For further
V5 = information, see ULS Device Driver in
V6 = Chapter 8.

V16 =
BV0 = 0 These 8-bit values, which range from 0-255,
BV1 = 0
are assumed to be the initial state of the control
lines of a CNC machine when the system is
turned on.
PORT0 = 0x500 I/O port addresses on a Station Manager PC
PORT1 = 0X501
that are mapped to the status and control lines
of a CNC machine using a special interface
card. These values should match the jumper
settings on the I/O card.
[DEBUG]
Protocol=YES
PLC Device Driver Settings

[General]
CimSetupPath=..\CIMCELL\SETUP\SETUP.CIM See this parameter in the ACL section above.
[PLCDriverDefinitions]
Type = OMRON The type of PLC being used. This value
determines what communications protocol is
used between the device driver and the PLC.
SimulationStations = 3,6,1,2,4,5,7 In Simulation or Manual mode, this parameter
sets the order in which the stations appear.
SimulationPallets = 8 In Simulation mode or Manual mode, this
parameter specifies the number of pallets
traveling on the simulated conveyor.

Inside OpenCIM
SimulationPosPerStation = 3,3,3,3,3,3,3 In Simulation or Manual mode, this parameter
specifies the distance between each station as
measured in pallet lengths, i.e. the number of
pallets that would fit on the simulated conveyor
between two stations. The position of each
number here corresponds to the order of
stations as listed in the parameter
SimulationStations. For example, the
distance between stations 4 and 5 below is 8
pallets long:
SimulationStations = 3,6,1,2,4,5,7
SimulationPosPerStation = 3,5,7,4,8,3,5
SimulationDirection = L In Simulation or Manual mode, this parameter
specifies the direction in which the simulated
conveyor travels.
L = Clockwise
R = Counter-clockwise
BaudRate = 9600 RS232 parameters used by this device driver
Parity = Even
DataBits = 7
when it communicates with the PLC. You must
StopBits = 2 set these parameters to match the RS232
XonXoff = No settings on the PLC.
MainWindowBkgndColors = 150,0,170 See these parameters in the ACL section above.

Inside OpenCIM
VC2_WM.DBF
The VC2_WM.DBF (Virtual Controller Series 2, Windows Messages Database File)
contains the following fields:
DDE_CHNNL The type of device driver that sends this message. This value must
be one of the following (in lower case):
dde_acl
dde_cnc
dde_plc
dde_cim
dde_rvp
dde_olmt
dde_asrs
dde_lsm
WM_INPUT The ID of the message to be sent.
NAME_WS Name of destination workstation that is to receive this message (as
specified in the file MAP.INI).
NAME_DDE The type of device that receives this message (e.g. dde_cim for
the CIM Manager).
WM_ This number identifies the type of message being sent.
ID_DEVICE Device ID of the receiver as specified in the file SETUP.CIM. If a
device does not appear in SETUP.CIM, this value will be 0 (e.g.
the CIM Manager, the Graphic Tracking Module, an ASRS).
NOTE A description of this message (free text).
The term DDE stands for MS-Windows Dynamic Data Exchange. OpenCIM device drivers
do not currently use DDE but this term remains in the above field names for backward
Note
compatibility.
The following table shows the standard OpenCIM messages contained in VC2_WM.DBF:
External CIM Message Description
Message
2225 Robot Start from ACL
2226 Robot Finish from ACL
2230 Robot End from ACL
2335 Pallet Stop from PLC
2336 Pallet Pass from PLC
2337 Error from PLC
2338 Arrive Free Pallet from PLC
2229 Error from ACL
2339 Complex Pass Message from PLC to OLMT
2580 CNC End from CNC
2576 CNC Error from CNC
2581 CNC Start from CNC

Inside OpenCIM
External CIM Message Description
Message
2582 CNC Finish from CNC
2138 ACL to CNC Request
2137 ACL to CNC String
2195 QC Result
2358 Device is ready
2583 CNC Task is loaded
2359 Device is unavailable

Inside OpenCIM
OpenCIM Database Structure
The OpenCIM database is compatible with the Xbase database management programs (e.g.
dBASE, FoxPro and Clipper).
The OpenCIM database consists of the following files:
File Description
PART_DEF.DBF Created by the Part Definition program.
PART_PRC.DBF
MACHINE.DBF Created by the Machine Definition program.
PROCESS.DBF
TEMPLATE.DBF Created by the Storage Definition program.
STORAGE.DBF Created by the CIM Manager and is maintained by the Storage
Definition program.
ORDER.DBF Created by the Order Entry program.
APLAN.DBF Created by the Order Entry program through the APLAN.EXE
program.
CIMREP.DBF Created by the CIM Manager.
LEAFPART.DBF
SCHEDULER.DBF Created by the CIM Scheduler program
PERFORMANCE.DBF Created by the performance program
OPT_MQUEUE.DBF Created by the Optimization program
PURCHASE.DBF Created by the Order Entry program
CUSTOMER.DBF
SUPPLIER.DBF
The following tables describe the structure of the files that compose the OpenCIM database.
Fld # Field Name Type Width
PART_DEF.DBF File Structure
1 PART Character 20
2 DESCRIPT Character 40
3 ID Numeric 4
4 TEMPLATES Character 15
5 RACKS Character 15
6 SETUPTIME Numeric 8
7 LEADTIME Numeric 8
8 PRODUCT Logical 1
9 SUPLIED Logical 1
10 PHANTOM Logical 1
11 COST Numeric 6
12 SUPLIER Character 30
Inside OpenCIM
13 SUPTIME Numeric 8
14 PCTLOST Numeric 2
15 MINORDER Numeric 4
16 CAPACITY Numeric 2
17 CATNUMBER Character 30
18 SAFSTOCK Character 5
PART_PRC.DBF File Structure
1 PART Character 20
2 SEQNO Numeric 2
3 SUBPART Character 20
4 PROCESS Character 20
5 PARAMETERS Character 30
6 ORDERING Logical 1
MACHINE.DBF File Structure
1 SERVER Character 20
2 COST Numeric 6
3 NBUFFER Numeric 1
4 NRACK Numeric 1
5 NCONVEYOR Numeric 1
6 NMAX Numeric 2
7 QUETYPE Character 4
8 QUEVEC1 Numeric 4
9 QUEVEC2 Numeric 4
10 QUEVEC3 Numeric 4
14 NPRELOAD Numeric 2
15 PRG1 Character 80
16 DATE1 Date 8
18 DATE2 Date 8
20 DATE3 Date 8

Inside OpenCIM
22 DATE4 Date 8
24 DATE5 Date 8
25 LASTLOADED Numeric 1
PROCESS.DBF File
2 ACTIONYPE Character 12
4 FILE Character 80
5 PROGRAM Character 20
6 ARGCNT Character 20
7 PARAMETERS Character 40
8 FAILPRCNT Numeric 2
9 DURATION Character 8
10 NEED ROBOT Character 3
TEMPLATE.DBF File Structure
1 BAR_CODE Character 6
STORAGE.DBF File Structure
1 SERVERID Numeric 4
3 INDEX Numeric 3
4 TYPE Character 1
5 SUBTYPE Numeric 3
6 STATUS Numeric 1
7 PARTID Numeric 4
8 PARTNAME Character 20
9 PARTPOS Numeric 4
10 TEMPLTID Numeric 4
11 TEMPLATE Character 20
12 TEMPLTPOS Numeric 4
ORDER.DBF File Structure
1 SEQNO Numeric 2
2 PART Character 20
3 ITEMS Numeric 3
4 FIRSTDO Numeric

Inside OpenCIM
5 NEXTDO Numeric 2
6 PRIORITY Numeric 2
7 TARGET Character 20
8 NOTE Character 40
9 DUEDATE Date 8
10 DUETIME Character 8
11 DONE Numeric 3
12 FAIL Numeric 3
13 INPROCESS Numeric 3
14 EXPDATE Date 8
15 EXTIME Character 8
APLAN.DBF File Structure
1 PART Character 20
2 SEQNO Numeric 2
5 TARGET Character 20
6 INDEX Character 20
8 PARAMETER Character 80
CStOrder.DBF File Structure
1 CUSTNAME Character 20
2 PART Character 20
3 ITEMS Numeric 3
4 DONE Numeric 3
5 PRIORITY Numeric 2
6 DUEDATE Date 10
7 DUEPERIOD Character 8
8 MANINDEX Numeric 8
Customer.DBF File Structure
1 CUSTNAME Character 20
2 DESC Character 80
3 ADDRESS Character 40
4 PHONE Character 25
5 FAX Character 25

Inside OpenCIM
6 EMAIL Character 25
Orderlist.DBF File Structure
1 SEQNO 2
2 PCONTROL Character 1
3 DESC Character 80
PURCHASE.DBF File Structure
1 SUPPLIER Character 20
2 PART Character 20
3 SPART Character 20
4 ITEMS Numeric 3
5 COST Numeric 6
6 DUEDATE Numeric 6
7 SENDDATE Numeric 6
SUPPLIER.DBF File Structure
1 SUPPLIER Character 20
2 DESC Character 80
3 ADDRESS Character 40
4 PHONE Character 25
5 FAX Character 25
6 EMAIL Character 25
REPORT.DBF File Structure
1 NAME Character 20
2 REPORTNAME Character 120
3 DESTINATION Character 30
4 NOTE Character 80
SCHEDULER.DBF File Structure
1 PART Character 20
3 MACHINE Character 20
4 ORDERNUMB Numeric 3
5 PLNSTART Character 8
6 PLNFINISH Character 8
7 PLDURATION Character 8
8 ACTSTART Character 8
9 ACTFINISH Character 8

Inside OpenCIM
10 ACTDURATION Character 8
11 STATUS Numeric 2
LEAFPART.DBF File Structure
1 ID Numeric 2
2 NAME Character 20
3 ORDER_NO Numeric 3
4 IDLIST Character 80
5 ACTION_POS Numeric 3
6 ACTION_SUB Numeric 3
7 ACTION_TYPE Numeric 3
8 STATUS Numeric 1
CIMREP.DBF File Structure
1 CODE Character 20
2 ORDER Character 20
3 ORDERSEQ Character 20
4 PART Character 20
5 PARTID Numeric 4
6 DEVICE Character 20
7 DEVICEID Numeric 4
8 ACTION Character 20
9 ACTIONID Numeric 4
11 SUBPARTID Numeric 4
12 WHICYH Character 20
13 INDEX Numeric 3
14 STATION Character 20
15 TIME Character 8
16 DATE Date 10
PERFORMANCE.DBF File Structure
2 ORDERID Character 5
3 TOTALTIME Character 17
4 PROCTIME Character 17
5 EFFICIENCY Character 10

Inside OpenCIM
6 MAXQUELEN Character 4
7 COST Character 15
8 SETUPS Character 4
9 FAILPRCNT Character 10
10 NOTE Character 80
OPT_MQUEUE.DBF Structure
2 ALGNAME Character 30
3 ALGWEIGHT Character 3
4 ACTIVE Character 3
5 FIN2FIN Character
6 Note Character 80
Application to Report File Cross Reference

The following table links the specific OpenCIM application to the database file name, the
report name and the report template file name.
Application Database File Name Report Name Report Template
File Name
Part Definition PART_DEF.DBF Part Report part.rpt
PART_PRC.DBF PRocess Report proces.rpt
Product Tree partprocess.rpt
Machine Definition MACHINE.DBF Machine machine.rpt
Definition Report
Storage Definition STORAGE.DBF AS/RS Report ASRS.rpt

(ASRS)
CIM Manager CIMREP.DBF Analysis Report Analysis.rpt
(Created by)
CIM Manager and STORAGE.DBF Location Status Location.rpt
ASRS Report
MRP APLAN.DBF Aplan Report Aplan.rpt
ORDER.DBF Order Report order.rpt
PURCHASE.DBF Purchase report Purchase.rpt
Performance Performance*.D Performance performance.rp
BF Report t
Optimization OPT_MQUEUE*.DB Optimization Optimization.r
F Settings Report pt
Report Generator PART_DEF.DBF
Part Definition Part.rpt

Inside OpenCIM
PART_PRC.DBF Sub. part Subpart.rpt
PART_PRC.DBF Process Process.rpt
Machine
MACHINE.DBF Definition Machine.rpt
STORAGE.DBF Storage Definition asrs.rpt
PURCHASE.DBF Purchase purchase.rpt
Manufacturing
ORDER.DBF Order order.rpt
APLAN.DBF Aplan aplan.rpt
CIMREP.DBF Analysis analysis.rpt
STORAGE.DBF Location location.rpt

Inside OpenCIM
Software Backup
Since system files could be altered or destroyed, it is recommended that you keep backup
files of your OpenCIM system. The backup files can be used to restore the system if
necessary.
The backup procedure involves three stages:
Back up the ACL controllers to the Station Manager Pcs (detailed in Chapter 8).
Back up the Station manager PCs to the CIM Manager PC.
Back up the CIM Manager PC to a backup disk.
These procedures should be performed by the system supervisor only.

Do not perform Backup procedures while the OpenCIM is running because currently running
Notes
programs may be aborted and data files may be in an unstable state.
Always keep robot positions, ACL programs and parameters on disk.
Backup and restore the entire system regularly to ensure good backup at all times.
The following procedure backs up a CIM cell directory.
1. Back up the ACL controllers to a backup folder in each WSn
folder in the Manager PC.

Procedure 2. Place all relevant data of a CIM cell under its folder in the
Backing up the Manager PC.
OpenCIM System 3. Compress the CIM cell folder using Winzip.
4. Make copies of the compressed folder to your backup disk
It is recommended that you also make separate backup files of the following items:
Robot Points Robot point coordinates are associated with the station PC
connected to an ACL controller. These points can change
whenever a new product is defined, an existing product
definition changes, or a robot (or any other device) is moved.
Gcode and process These files contain the process program of the CNC machines
programs files or/and other processing machines.
QC script files These files contain the Quality Control procedures.

Inside OpenCIM
13
Errors and Troubleshooting
This chapter describes how to handle device errors, troubleshooting and so on. It includes the
following sections:
Device Error Handling, describes the device error window that
appears whenever a problem is detected with a specific machine or a
robot as well the information referring to occurring problems.
Troubleshooting, describes various trouble shooting procedures
enabling you to identify the problems.
Error Messages, lists the OpenCIM error messages.
Contacting Technical Support, describes how to contact Intelitek or
your local distributor for assistance and displays the problem report
form.

Device Error Handling
The Device Error screen appears whenever a problem is detected with a specific machine or
a robot. This screen allows you to determine how to deal with an error without having to
reset the entire CIM.
Figure 13-1: Device Error Screen

Device errors can be caused by various factors, including:
Robot collision
Device breakdown
Defective part which does not properly fit into a machine or robot
Machine running out of supplies for a given process
The Device Error screen gives you complete information about what was happening at the
time that the problem occurred. It identifies the current part that was being processed
(current process) when the error occurred. You can then choose what to do in order to
recover from the error.
This screen is divided into the following sections:
Where the problem occurred (top)
What the problem is (middle)
How to proceed (bottom)
Where the Problem Occurred

The following table describes information referring to a problem that occurred in OpenCIM.
This includes the station where the problem occurred, the part that was being processed
when the problem occurred and so on.
Station The name of the workstation PC where the problem occurred (e.g. WS 03).
Part The ID of the current part that was being processed when the error
occurred.
Device The name of the robot or machine that experienced the problem.

Next Process The name of the process that was to be performed on the Next Machine
(described below). By examining the Process table for the current part, you
can determine exactly where the production process was interrupted (select
the current part on the Part Definition form).
Order ID The entry in the Order table that was interrupted by the error.
Next Machine The name of the next machine that was to process the current part. This
information is especially useful when a robot error occurs. The Next
Machine field tells you where the robot was supposed to deliver the current
part when the error occurred.
Action The CIM production command (A-plan action) that was being carried out
when the error occurred.
What the Problem Is

All fields described in this section are optional. For a given error message, only those fields
for which information is available will display.
Error Message The text of the error message generated by the control program (e.g. robot
program, G-code, etc.) that was running when the error occurred.
Error No. The error code returned by the control program.
Program Name The name of the program that was running when the error occurred.
Program ID The ID number of the control program.
Program Line # The line in the control program that generated the error.
Source Location The place where the current part resided prior to the error. This field
consists of a location ID followed by an index number if appropriate
(e.g. a slot number in a rack).
Target Location The place where the current part was to go next if the error had not
occurred. This field consists of a location ID followed by an index number
if appropriate (e.g. a slot number in a rack).
How to Proceed
In order to continue operation, two tasks must be accomplished:
The part should be placed where the next process assumes the part is to be found.
The proper messages must be sent to the CIM Manager so that it can activate the next
process.
In most cases, the safest and easiest way to accomplish these tasks is to:
1. Remove the source of the problem.
2. Cause the device to repeat the operation. This is done by sending the device the
appropriate command from the device driver. Then the CIM Manager ignores the
reported error because the problem for the device has already been corrected.
Ignore Process successfully completed; ignore the error and resume production.
If the current process was successfully completed (with or without help
from the operator), clicking the Ignore button causes the CIM Manager to
ignore the cause of the error and proceed with normal processing of the
current part.

Caution
Before you select Ignore, make sure that:
The current part has not been damaged as a result of the error.
The cause of the error will not recur.
The current part is in the proper position to be handled by the next
process.
Retry Reserved for future use.
Fail Reserved for future use.

How to Recover a Failed Device
If a device fails to operate (for example a CNC machine), the CIM-Device Error! screen
appears. To recover:
1. Go to the device that has failed (CNC, Robot, QC or PLC) and abort
all programs.

Procedure 2. Find the problem and correct it.
Recovering a Failed 3. Return to the CIM Manger PC and select Ignore in the CIM Device
Device Error! screen. The manager assumes that the last operation was
completed and continues on to the next operation.
Example 1: While running the application, a robot goes into impact
protection and the CIM-Device Error! screen appears on your CIM
Manger PC.
1. Refer to the Robot user manual and take corresponding actions to
abort the current program.
2. If appropriate (depending on specific robot controller type), initialize
the controller.
3. Verify that the robot is in free space and then type Run Homes. Wait
until the robot has finished homing.
4. Return to the CIM Manger PC and select Ignore in the CIM Device
Error! screen.
5. According to the type of controller, try to run the last submitted Pick
and Place sequence.
Example 2: While running the application, the CNC fails and the CIM-
Device Error! screen appears on your CIM Manger PC.
1. Go to the CNC device driver.
2. Find the problem in the CNC machine and correct it.
3. Load the machine again (manually) with its supplied part.
4. Prepare the machine for Cycle Start.
5. Return to the CIM Manger PC and select Ignore in the CIM Device
Error! screen
6. Using the CNC device driver, return to the last operation (normally
Operate0). Wait until the CNC finishes its G-code.
7. Return manually to the last OpenCIM operation using that device
driver.

Troubleshooting
If the installation and startup procedures detailed in your system user manual were closely
followed, your OpenCIM system will give you reliable service. If a problem should occur,
the first step in the troubleshooting procedure is to identify the problem and its source.
If you encounter problems accessing the Web Viewer, verify that the Internet Explorer
Security Settings are set to the default settings.
The OpenCIM system has been designed to simplify troubleshooting procedures by using the
CIM-Device Error! dialog box.
When troubleshooting, pay careful attention to the following general warnings:
Have all personnel remain clear of the robot envelope, CNC machines, Quality
Warning Control machines and all other equipment when power is applied. The problem
may be intermittent and sudden unexpected robot or equipment motion could result
in injury.
Have someone ready to operate an emergency Stop switch in case it becomes
necessary to shut off power to the robots CNC machines, QC machines, etc.
Never reach into a machine or robot to actuate a switch because unexpected
machine or robot motion could occur, causing injury.
Remove all electrical power at the main, and turn off all switches before checking
electrical connections or any inputs/outputs which could cause robot or machine
motion.

There are several cases of alteration that can occur to the OpenCIM programs, including
extreme environmental conditions, electromagnetic interference, improper grounding,
improper wiring connection and unauthorized tampering. If you suspect the memory of the
PC has been altered, scan the disk with the appropriate utility.
Problem Solution
17. If you receive one of Reset your PC, and perform a disk scan.
the following
messages:
General Protection
Error...
Assertion Failed...
An Error has occurred
in your application...
18. OpenCIM tells you This is not a real problem. This occurs when
that it has received an someone clicks the mouse on one of the OpenCIM
unknown message. device drivers and activates a procedure.
19. The system is running ACL:
but the robot Device Verify that the ACL controller is in CON mode.
Driver is not
Verify that ACL Controller-A is in Motors ON.
responding to CIM
Manager. Try to run the failed command again from the
control panel of the ACL device driver.
Verify that your MAP.INI is correct.
Review the robot and controller user manuals, and
check if the robot system is operational and is
communicating with OpenCIM.
Scorbase:
Verify that you have a single Network Connection in
the System Network Connections Window.
Verify that you are working in StandAlone mode.
Verify that your TCP/IP status is enabled. To do so:
Click the TCP/IP icon on the toolbar and select
Enable TCP/IP if it is disabled.
20. While the system is Turn the PLC off and then turn it on again.
running, a pallet stops Verify for each pallet, that it stops and releases at
in the wrong each station.
destination or does not Start the PLC device driver. Place only one pallet on
stop in the correct the conveyor and follow the report on the PLC
position. device driver control panel.
Verify that the correct pallet ID is reported for each
station as the pallet passes.
Repeat the same test for each pallet.
Using the control panel, deliver one of the pallets to
one of the stations and release it (refer to The PLC
Device Driver for more details on operating the
PLC device driver).

Problem Solution
21. The system is running Verify that the PLC is on.
but the PLC is not Verify that you are able to operate the PLC from the
responding. control panel.
22. The system is running Verify that your MAP.INI is correct.
but the RVP is not Verify that the RVP is in the automatic mode and
responding. you received the prompt >.
23. The system is running Try to operate the CNC machine from own board.
but the CNC does not Verify that the CNC is in the mode designated by
respond. your system users manual.
Try to operate the CNC machine from the CNC
device driver.
24. You try to run the Verify that your MAP.INI is correct.
system and the yellow Check the OpenCIM Debug dialog box. If Error 8
Wait message appears is displayed then reboot your PC.
(after waiting there is
still no change).
25. One of the OpenCIM Using the File Manager, verify that the project
applications is unable directory (on the main PC) is a shared directory.
to locate one of its Verify that your PC is connected to the main PC
source files in the according to your identification in all your local INI
setup directory. files.
26. The barcode fails a If your barcode is operated by an ACL controller,
good template. verify that in your Part Definition form you entered
the following:
PROCESS column : READC
PARAMETERS column: $TEMPLATETYPE
27. The CIM Manager is In the Machine Definition form, verify that the field
running, but gets stuck List of Preloaded Programs is not empty.
after the CNC process.
28. The ACL driver can Verify that the ACL controller is on.
not establish Verify that the motors are on.
communication with
the robot. Verify that no other application is using the same
COM port (e.g. ATS, ACL Off line).
Exit Windows and start the ATS using the correct
COM port. If the problem still exists, refer to the
ATS manual.
Start Windows and then start the ACL device driver.
If the problem still exists, exit the device driver and
verify the COM port in the ACL.INI file.

Problem Solution
29. The following Change to On-line mode.
communication error Make sure the connecting cable is properly
message appears while connected to the Controller-USB and to the
operating the robot computer.
from a PC with
Scorbase: No If the problem persists, replace the USB cable.
communication Reinstall the USB driver. Refer to the section USB
between Controller- Driver Installation below.
USB and computer.
The Power LED is
orange.
30. A device driver is This error message indicates that the device driver could not
unable to open an open the serial port on the Station Manager PC. Possible
RS232 port in order to causes include:
communicate with its The port is in use by another application.
device, and displays
the following message The port number is invalid.
in the Control Mode One of the serial port parameters is invalid.
box: Cannot Open
Com:n
31. The ViewFlex device Verify that your MAP.INI is correct.
driver can not Verify that script file directory is defined correctly in
establish the VFVD.INI file.
communication with
the Manager Verify that Viewflex device driver is in On line
mode.

Error Messages
Several errors shown in the list below are related to setup problems. The Virtual CIM Setup stores its
information in the file SETUP.CIM.
Code Description and Solution
9001 Undefined Part
Set up this part using the Part Definition module.
9002 Internal Error
Call Intelitek technical support.
9003 A Start Operation message was received when no operation was requested.
9004 A Finish Operation message was received when no operation was requested.
9005 An End Operation message was received when no operation was requested.
Check the ACL program or CNC or Scorbase script associated with the
current process that may be sending an erroneous Start, Finish, or End
message. OR
Someone has manually triggered a Start, Finish, or End message by running a
program from the Control Panel of either the ACL or CNC device driver.
9006 Unrecognized device, location, or part.
Define the unrecognized device or location using the Setup module. OR
Define an unrecognized part using the Part Definition module.
9007 Cannot perform this process. Either the process definition or device definition is
missing.
Define the unrecognized process using the Machine Definition module. OR
Define the unrecognized device using the Setup module.
9008 Start message received from an unrecognized device.
9009 Finish message received from an unrecognized device.
9010 End message received from an unrecognized device.
9011 Error message received from an unrecognized device.
Someone has manually triggered a Start, Finish, End or Error message by
running a program from the Control Panel of either the ACL or CNC device
driver. OR
Check if the ACL program or CNC script that sent the message is using an
invalid device ID ($ID). OR
Incorrect assignment of a device to a device driver in the file VC2.MAP. OR
The device ID on the device driver command line is incorrect. OR
Define the unrecognized device using the Setup module. OR
9012 This location has not been assigned to a robot.
Use the Setup program to make this assignment.
9013 The file SETUP.CIM is missing from the working directory.

Copy a backup version of this file to the working directory. OR

Run the Setup module to create a new setup file from scratch.
9014 Unable to transfer this part to its next destination.
No path has been defined between the part's current location and its next
destination. Use the Setup module to link these two locations. OR
Internal Error. Call Intelitek technical support.
9015 Cannot move part because its destination location is already occupied.
9016 The robot has received a command to continue an operation that it has not started.
Add the Move command to the Part Definition table to have the robot grab
the part first.
9017 Invalid Storage Device. A request was received to retrieve a part from a location that
is not a storage device.
Use the Setup module to define the target device as a storage device. OR
Use the Part Definition module to change the target device to be a valid
storage device.
9018 This part is not available to the current process.
Check the Part Definition table.
9019 A quality control result was received when no QC test was requested.
Check if an ACL program or CNC script is sending an incorrect message.
OR
Someone has manually triggered a quality control result by running a
program from the Control Panel of either the ACL or CNC device driver.
9020 Reserved for future use.
9021 An unexpected status message was received. There was no corresponding command
message sent.
Check if an ACL program has assigned an invalid value to the variable $ID
(the task ID). OR
Check if a CNC program has assigned an invalid value to the variable $ID.
OR
Device driver internal error. Call Intelitek technical support.
9023 Invalid storage index.
Use the Setup module to increase the value of the Capacity field for this
storage device. OR
Use the Part Definition module to ensure that the storage index specified in
the Parameter field of the Part Definition table is within the range of the
Capacity field for this device.
9024 Part is not available at this storage location.

Use the Storage Definition module to update the storage contents. OR

Abort this order if there are not enough parts to complete it.
9025 Invalid location index for a machine.
Use the Setup module to increase this machines part capacity. OR
9026 Undefined process.
Add this process to a suitable machine using the Machine Definition module.
OR
Modify the Part Definition table to use a valid process.
9027 No template buffer has been defined for this station.
Use the Setup module to add a buffer.
9028 Process cannot be performed because the machine is not defined in the file
SETUP.CIM.
Use the Part Definition module to specify a different process in the Part
Definition table. OR
Use the Setup module to define this machine.
9029 Inconsistent value in the inventory database file STORAGE.DBF.
Rebuild the storage data by adding the /INIT switch to the CIM Manager
command line (CIM.EXE). OR
Check the CIM Managers INI file (usually OPENCIM.INI) to ensure that
the parameter CimDataDir in the [General] section is the same as that
in the INI file for the Storage Definition module.
If you want to restore a known good copy of the file STORAGE.DBF, click
on the Refresh Storage icon on the Program Manager screen (or manually
copy this file from a backup).
9030 Machine not defined in file SETUP.CIM.
Use the Machine Definition module to set up this machine.
9031 The requested G-code task has not been assigned to a CNC machine.
Use the Machine Definition module to assign this task to this CNC machine.
9034 Unexpected ONFAIL process.
Use the Part Definition module to edit the Part Definition table so that
ONFAIL only appears immediately after a quality control process.
9035 No ONFAIL process immediately after a quality control test.
Use the Part Definition module to edit the Part Definition table so that
ONFAIL appears immediately after this quality control process.

9037 Error in A-Plan Place command.
Internal Error. Call Intlitek technical support.
9038 Error in A-Plan Next command.
9040 The parameter ConPallet (maximum # of pallets) is not defined in the file
SETUP.CIM.
Add ConPallet assignment to SETUP.CIM.
9041 Cannot start the CIM Manager because it is already running on this PC.
Switch to the window in which the CIM Manager is running.
9043 Invalid status message. Received an unexpected quality control result from a non-QC
device.
Check an ACL program or CNC script that might be sending an incorrect
message.
9045 Invalid status message. A bar code result was received when no operation was
requested. Result ignored.
Someone has manually triggered a bar code result by running a bar code
program from an ACL Control Panel. OR
Check an ACL program or CNC script that might be sending an incorrect
message.
9046 Machine queue overflow - Too many parts are waiting to use this machine.
Use the Order Entry module to decrease the initial quantity ordered for parts that use
this machine.
9048 No status message was received after a command was sent because this device driver
was reset.
Select how you would like to continue from the options shown on the Device
Error screen.
9049 No status message was received after a command was sent because this device driver
is not running.
Select how you would like to continue from the options shown on the Device
Error screen.
9050 DBF handler error - Request to use an inactive field.
9051 DBF handler error - Record number less than 1.

Contacting Technical Support
If you need to contact Intelitek or your local distributor for assistance, please fill out a photocopy of
the Problem Report Form below and fax it to us. Contact information can be found at
http://www.intelitek.com/contact.asp
To Intelitek - Technical Support Department Fax:
From: ___________________________________________ Date: ________________
Company: ____________________ Fax: _______________ Tel #: ________________

Problem Report Form
Product name: ___________________________________________________________________
Installed at: ______________________________________________________________________
Serial numbers of all relevant Intelitek elements: ________________________________________

_______________________________________________________________________________
Date of purchase or invoice number: __________________________________________________
Version number and date of every Intelitek software used (the information appears on the
first screen of every software supplied, and through the ACL command VER regarding
EPROMs):
software: version: date:

Detailed descriptions of the problem, including (but not only) all the steps which led up to
the problem arising, since the start-up of the system (attach more pages if necessary):
_______________________________________________________________________________
_______________________________________________________________________________
Error messages as they appear on the display (PC screen, TP LCD, PLC LEDs, etc.):
_______________________________________________________________________________
_______________________________________________________________________________
List all changes introduced to the system since the last time the system worked properly:
_______________________________________________________________________________
_______________________________________________________________________________
For robots: List of accessories and I/Os connected to controller and type of gripper attached
to arm: _________________________________________________________________________________
_______________________________________________________________________________
Attach a printout of all the control parameters.
For computers: Computer type, DOS version and manufacturer:____________________________
List of cards added (LAN, modem, etc): _______________________________________________

Attach a printout of the AUTOEXEC.BAT and CONFIG.SYS file.

14
Glossary
This chapter contains the various abbreviations and terminology used in OpenCIM. It
Abbreviations, contains a list of the acronyms used in OpenCIM, as
well as their descriptions.
Terminology, contains a list of the OpenCIM terminology, as well as
their descriptions.

Glossary
Abbreviations
Abbreviation Explanation
ACK Acknowledge
ACL Advanced Control Language
AGV Autonomous Guided Vehicle
ASRS Automated Storage and Retrieval System
ATS Advanced Terminal Software
BMP BitMaP (the file extension representing the Windows native bitmap
picture format)
bps bits per second
CIM Computer Integrated Manufacturing
CNC Computer Numerically Controlled
DBF Database File (in dBASE format)
DD Device Driver
FIFO First In, First Out
FMS Flexible Manufacturing System
GT Get part (robot operation)
LAN Local Area Network
LIFO Last In, First Out
LSM Laser Scan Meter
MRP Material Resource Planning
NACK Negative Acknowledgment
PLC Programmable Logic Controller
PP Pick-and-Place (robot operation)
PT Put Part (robot operation)
QC Quality Control
RV Robot Vision
TCP/IP Transmission Control Protocol - Internet Protocol
WMF Windows Meta Format (the file extension representing the Windows
native vector picture format)
WS Workstation

Glossary
Terminology
Term Explanation
ACL Robotic programming language used to control robots and
peripheral equipment attached to Inteliteks ACL controllers
(Advanced Control Language).
ACL A multitasking computer used to direct the operations of a
Controller robot(s) and peripheral devices in real-time.
ASRS A robotic storage device used to store and dispense parts in a
CIM cell.
Assembly A part which has been put together from two or more
subparts.
ATS A PC based terminal emulation program used to program an
ACL controller (Advanced Terminal Software).
Baud Rate An RS232 parameter specifying the speed of the serial
connection.
Bill of A structured list of all the materials or parts needed to
Materials produce a particular finished product or subpart.
Buffer A buffer is a tray designed to hold a template when it is
removed from the conveyor. It is attached to the outer rim of
the conveyor at a station.
CIM The central control program of OpenCIM. This program
Manager directs production in the CIM cell using a variety of
communication networks. It also allows the user to set up
and define CIM elements.
Com Port See RS232.
Control A program which manages the operation of a CIM device
Program such as a robot (ACL program), a CNC machine (G-code), a
camera (ROBOTVISIONpro program), etc. A control
program communicates with the OpenCIM system via a
device driver at a Station Manager PC. The computer which
executes a control program can reside in: A separate
controller unit (e.g. an ACL controller) In the device itself
(e.g. a CNC machine with embedded controller) A separate
PC controlling the device (e.g. a PC attached to a
ROBOTVISIONpro camera)
DBF A file extension indicating Data Base File (i.e. in dBASE
format).
Device A program which knows how to communicate with a given
Driver piece of equipment that is connected to a PC. It translates
commands from other programs into a format understood by
the device. It also translates information coming from the
device into a format understood by other programs.
OpenCIM uses device drivers to communicate with robot
controllers, CNC machines, and quality control devices.

Glossary
Term Explanation
Download The act of sending a file(s) from one computer system to
another.
Feeder A device which dispenses parts at station (typically to a
robot).
FMS Flexible Manufacturing System; refers to either a CIM cell
or a station in a CIM cell.
Free A region approximately meter above the work surface in
Movement which the robot can move freely and quickly between
Zone locations without encountering any obstacles. See also Pick-
and-Place.
G-Code A program that directs the operation of a CNC machine. See
also Control Program.
Group A, B Used in the context of programming robot positions using
ACL. A group refers to a set of axes of movement that apply
to a device (e.g. robot, X-Y table). The device can move
along all axes in its group simultaneously.
GT The name of a generic ACL program used to direct a robot
to pick up a part at a designated location.
Home a A procedure used to reset a robot to known starting position.
Robot
INI File A text file containing settings for various OpenCIM
parameters. Parameters are grouped into sections. The
structure of OpenCIM INI files is similar to that of other
standard Windows INI files such as WIN.INI.
I/O (Input / A low voltage connection used for binary signaling between
Output) devices (i.e. on or off). An input is used to read the status of
a device. An output is used to turn a designated operation on
or off.
Load An operation which uses a robot to insert a part into a CNC
machine.
Loader A program which automates the start-up of the OpenCIM
system under Windows based on command line parameters
found in an INI file.
Machine A CIM device (other than a robot) which performs
production processes (e.g. CNC machine, laser scan meter,
etc.).
Machine A device (e.g. a robot) which delivers and retrieves parts
Tending from a machine.
Material See Part.
Order Instructs the CIM system which part(s) to produce and in
what quantity.
Pallet A tray which travels on the conveyor and is designed to
carry a template.

Glossary
Term Explanation
Part An entity which moves between stations and machines
according to a predefined path, or process. Three types of
parts can be defined: supplied, phantom, and final product.
Part Family A group of parts which are handled the same way by a robot
(i.e. the same ACL program can be used to pick-and-place
parts in the same family).
Pick-and- The primary robot function which involves taking a part
Place from one location (source) and placing it at another location
(destination). The pick-and-place strategy minimizes the
number of ACL programs required to move parts between
two locations at a station. Each location has a GET and PUT
program associated with it. The GET program picks up a
part from the location. The PUT program places a part at
this location. All GET and PUT programs for a robot are
designed to work together to transfer a part from any
location to any other location.
PLC A device having several electrical inputs and outputs. A PLC
switches its outputs on and off in response to the state of its
inputs and the programming of its embedded computer. In
the OpenCIM system, a PLC is used to control the conveyor.
Points See Position.
Position The path a robot follows is made up of a set of predefined
points. Each point along this path is called a robot position.
The coordinates of each point are taught by using a teach
pendant or by running a special ACL program while leading
the robot by the nose and recording each stopping point
along the path.
Process A production activity (e.g. lathing, milling, assembly, QC
check, etc.) performed by a machine on a part.
Processed A part which results from the processing of a raw material.
Material
Product Something that is manufactured by the CIM cell. The CIM
begins production in response to orders placed for products.
PT The name of a generic ACL program used to direct a robot

to place a part at a designated location.
Quality Any process used to check whether a part is satisfactory or
Control not.
Rack A set of storage compartments used at some stations to store
parts either before or after they are processed at that station.
Each type of rack is assigned an ID number. Each
compartment in a rack is identified by a unique number.
Raw See Supplied Part.
Material

Glossary
Term Explanation
RS232 A common, low speed communication protocol which
allows a wide variety of devices to communicate with each
other (typically in the range of 300 - 19,200 bps). On a PC,
RS232 ports are referred to as COM1 - COM4.
Robot A device that moves parts from place to place at a station.
Some robots are also capable of assembling parts.
Robot Vision A quality control device which optically scans a part to
determine if it is satisfactory.
Serial Port See RS232.
Slidebase A peripheral device which enlarges the working envelope of
a robot by allowing it to move along a rail. The slide base
gives the robot an additional degree of freedom.
Station A location adjacent to the CIM conveyor which contains
production and/or storage equipment.
Subpart A part which undergoes some sort of processing in order to
be included in a higher level part.
Supplied Part A part which is the starting point for making a product. This
part (or material) is purchased and inserted into a CIM
storage location. It will later be processed by the CIM cell.
Template Plastic trays which can hold various types of parts. They
allow parts to be transported on the conveyor.
Unload An operation which uses a robot to remove a part from a
CNC machine.
Working The entire area in which a robot can reach.
Envelope
Xbase Any database management program that is compatible with
the dBASE standard for file formats and commands.

Glossary
15
Intelitek Software Licensing
The software is protected by a licensing agreement.
There are 2 license types: permanent and subscription (rent license).
If you purchase a permanent license you will receive a CD key from Intelitek.
If you purchase a subscription license you will receive a Subscription CD key from Intelitek.
If the software is installed without a license, you can use the fully operational software for a
14-day evaluation period. To continue using the software after this period it must be
unlocked.
The following sections contain detailed instructions on how to use the software license:
Register your software and receive a PC-specific unlock code for
each license purchased.
Protect your license.
Transfer a license from one PC to another PC for permanent license
type only.
Return the permanent license to Intelitek, so you can retrieve it later.
Frequently asked questions.

To register your Intelitek software follow these easy steps:
1. Install the software.
To register the software on Windows Vista/7, click on the Project Manager icon and select
Run as Administrator.
The first time you run the software, the Intelitek Software License dialog box appears.
Figure 15-1: Registration Dialog Box

2. Register using the method most convenient for you. We recommend registering online,
which is automatic.
To register a subscription license, select Subscription License, for the subscription CD key
fields to appear.
Figure 15-2: Subscription CD Key Fields

Registration Methods
The following descriptions of the different registration methods are relevant for both
permanent and subscription licensing.
The Intelitek Software License dialog box allows for three methods of registration:
Automatically from the Intelitek Website.
By E-mail
Manual Unlock
Automatically from the Intelitek Website.
You must have internet access available on the host PC.

Note
1. In the Intelitek Software License dialog box, select Online. Enter your CD key in the
appropriate fields. Your CD key can be found on the back of the CD case. It was also e-
mailed to you or sent to your team's main contact (for FIRST teams).
2. Click Unlock.
The software will automatically connect to Intelitek's website. An unlock code will
automatically be installed on your PC and a message will appear saying that the software is
now licensed.
By E-mail
1. In the Intelitek Software License dialog box, select E-mail as your registration
preference. Enter your CD key in the field below. Your CD key should be found on the
back of your CD case, and was either E-mailed to you or sent to your team's main
contact (for FIRST teams).
2. If E-mail is available on the host PC, a new email containing the required details will
open.
Figure 15-3: Intelitek Software License E-mail

Fill in all the requested user information, and send the message. The licensing service will
send back an unlock code, at which point you will complete a manual unlock (the third
registration option described below). This process is not automated and can take up to
several days.
3. If you have E-mail service, but not on the same computer on which the software is
installed, a Notepad window containing all required details will open. Fill in all the
requested user information, and then transfer the text/file to your email program. Be
sure you have included your PC specific code, and CD key in the email!
Send to: [email protected]
Subject: Intelitek Software License
Note: To ensure successful processing, use this exact subject line and do not edit the
automatically generated headings in the message. You may add your personal information
and comments into the body of the message.
Once you receive the unlock code, enter it in the Registration dialog box and select Unlock.
Manual Unlock
Manual Unlock registers your software without a CD Key by matching an Unlock Code to
your PC Specific Code. You can obtain an Unlock Code from Intelitek if you register by
email, or directly from another user after a license transfer.
1. In the Intelitek Software License dialog box, select Manual.
2. Enter the 8 digit alphanumeric Unlock Code in the field below. Click Unlock.
If the Unlock Code matches your PC Specific Code, your software will be licensed.
This completes the software registration procedure.

Permanent Licenses
Protect your permanent license
Every unlock code is unique. It will become invalid (and cause the software to stop
functioning) when you change a physical component in your PC (e.g., hard disk, network
card, CPU), format your disk, or install a new operating system.
1. If you want to upgrade your PC and keep your software operational, you
must first transfer the license (unlock code) to another PC.
2. Once you have upgraded your system, reinstall the software (if necessary)
and transfer the license back.
If you do not have a PC available for the temporary transfer operation, return the license to
Intelitek. You will be able to retrieve the license by following the standard procedure for
obtaining the unlock code.
Transfer a permanent license from one PC (source) to another PC

(target)
1. On the target PC install the software and get the PC-specific code from the Registration
dialog box.
2. On the source PC, open the Registration dialog box. Enter the PC-specific code of the
target PC and Select Transfer. The software on the source PC will generate a new
unlock code for the target PC and will remove the license from the source PC.
3. On the target PC, enter the new unlock code in the Registration dialog box.
Return a permanent license to Intelitek, so you can retrieve it later

Use this procedure when you need to remove a software license and do not have a target PC
available.
1. From the Registration dialog box, select Remove the License and click Remove. The
software will generate a unique Remove code.
2. Send the Remove code and your CD key to Intelitek using one of the methods described
above (email, website, fax/phone). We will confirm the codes and update our licensing
registration records.
3. When you are ready to retrieve your license, install the software (if necessary) and
follow the instructions for obtaining an unlock code.
4. The installation procedure generates a PC-specific code. This code is found in the
Registration dialog box.
To receive the unlock code for the software you installed, you must send Intelitek both the
CD key and the PC-specific code. The Registration dialog box provides several methods for
obtaining the unlock code.

FAQs Frequently Asked Questions
What is a CD key?
This is the code on a label on the CD. It allows Intelitek to track software that has been purchased.
What do I do if I do not have a CD key?
When prompted to enter the CD key during the software installation, enter the word evaluation.
This will allow you to install the software for a trial period.
What is a PC-specific code?
This is a code generated by the software. It is unique for each PC and each installation of the software.
This code allows Intelitek to generate the unlock code for the PC on which you installed the software.
The PC-specific code is displayed in the Registration dialog box.
What is an unlock code?
This is a code that allows you to use the software after the evaluation period expires. You need to
send your CD key and PC-specific code to Intelitek. We will reply with the unlock code for the
software you purchased.
How do I install and register the software on more than one PC?
Repeat the procedure for obtaining an unlock code as many times as necessary.
Alternately, install the software on all PCs and make a note of the PC-specific code generated on each
PC. You can then send us one email or fax listing all the PC-specific codes. You will receive unlock
codes for each PC. (Note: this will be handled manually by our technical support and may take several
days).
Why should I give you my personal details when I request the unlock code?
This will allow us to keep you informed about products, upgrades and services available for your
system and software. It will also allow us to help you in case of a lost license.
How can I recover the unlock code after a disk crash or other system failure?
Once you have restored and reactivated your PC, reinstall the software. If it resumes operation in
Evaluation mode, follow the procedure for obtaining an unlock code. Include a comment explaining
why you need a new unlock code. (Note: this will be handled manually by our technical support and
may take several days).
How can I extend the evaluation period?
To continue using the software after the evaluation period has expired, either a subscription (rent
license) or a permanent license must be purchased.


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OpenCIM

OpenCIM Offline and OpenFMS

Computer Integrated Manufacturing

Software Version 4.7

Introduction ....................................................................................................................................................... 1-1

System Overview................................................................................................................................................ 2-1

Safety .................................................................................................................................................................. 3-1

User Manual i OpenCIM

Project Manager ................................................................................................................................................ 5-1

Operating CIM Manager .................................................................................................................................. 6-1

User Manual ii OpenCIM

CIM Manager Utility Programs ....................................................................................................................... 7-1

User Manual iii OpenCIM

Virtual CIM Setup ............................................................................................................................................. 8-1

OpenCIM Device Drivers.................................................................................................................................. 9-1

User Manual iv OpenCIM

OpenCIM Programming ................................................................................................................................. 11-1

User Manual v OpenCIM

Inside OpenCIM .............................................................................................................................................. 12-1

Errors and Troubleshooting ........................................................................................................................... 13-1

Glossary ............................................................................................................................................................ 14-1

Intelitek Software Licensing ........................................................................................................................... 15-1

User Manual vi OpenCIM

User Manual 1-1 OpenCIM

User Manual 1-2 OpenCIM

User Manual 1-3 OpenCIM

User Manual 1-4 OpenCIM

User Manual 1-5 OpenCIM

User Manual 1-6 OpenCIM

User Manual 1-7 OpenCIM

User Manual 2-1 OpenCIM

User Manual 2-2 OpenCIM

OpenCIM Additional Software Packages

User Manual 2-3 OpenCIM

OpenCIM Sample Application - The Covered Box

Figure 2-1: Part Definition Tree for Sample Application

User Manual 2-4 OpenCIM

User Manual 2-5 OpenCIM

User Manual 2-6 OpenCIM

Figure 2-2: Schematic Example of an OpenCIM Cell

User Manual 2-7 OpenCIM

Figure 2-3: Sample OpenCIM Cell

User Manual 2-8 OpenCIM

Figure 2-4: An Empty Template

User Manual 2-9 OpenCIM

Figure 2-5: The ASRS2 Robotic Storage Station

User Manual 2-10 OpenCIM

Figure 2-6: Pallet at Conveyor Station

User Manual 2-11 OpenCIM

Robots and Controllers

User Manual 2-12 OpenCIM

User Manual 2-13 OpenCIM

User Manual 2-14 OpenCIM

The CIM Manager

The Station Manager

User Manual 2-15 OpenCIM

Figure 2-8: OpenCIM Modules Distributed Among PC's

User Manual 2-16 OpenCIM

Recommended PC requirements for OpenCIM software are:

Minimum PC requirements are: