AGILE PRODUCTION SIMULATION 24V

Instruction Manual

Version: 1
Model revision: 1.x
04/2024
Content
Quick Start Guide ............................................................................................................................ 2
Scope of delivery ........................................................................................................................... 2
Inspection for damage in transit ............................................................................................. 6
Available documentation .......................................................................................................... 7
Important notes ............................................................................................................................ 8
Setup and commissioning of the Agile Production Simulation ................................... 9
Structure of the Agile Production Simulation .................................................................... 9
Commissioning with a local application ............................................................................ 21
Commissioning with fischertechnik Cloud......................................................................... 31
1. Connecting the router to an Internet connection....................................................... 31
2. registration in the fischertechnik Cloud......................................................................... 32
3. coupling the APS with the fischertechnik Cloud ........................................................ 32
4. triggering the first order process via the cloud ........................................................... 33
Programming tasks for PLC development ......................................................................... 34
Task 1: Multiple milling .............................................................................................................. 35
Task 2: Extend OPC UA interface........................................................................................... 35
Technical documentation .......................................................................................................... 36

1
Quick Start Guide

Dear customer,

Thank you very much for choosing our product! This manual will guide you step by
step through the commissioning, from reviewing the scope of delivery to placing
an initial order for a workpiece in the Agile Production Simulation (referred to in
the following as the APS) locally and over the fischertechnik Cloud. Please take a
moment to read the instructions carefully.

Scope of delivery
 Eight base plates with modules and track guidance

The different available modules are on six of these base plates; these are listed in
the following section. There are also two track plates. These are connected
between the modules using pins when setting up the APS, so as to create a surface
on which the driverless transportation system (AGV) can move and transport
workpieces.

The following section describes the six modules that are mounted on base plates,
as well as the track plates:

1. Incoming / outgoing goods with 6-axis robot, Raspberry Pi 4B, WiFi

router and sensor station

2. High-bay warehouse

2
3. Drilling station

4. Milling station

5. Quality assurance with AI

6. Charging station

7. Two track plates

The AGV moves on these plates.

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● A AGV (Automated Guided Vehicle)
This system moves on the base plates and is responsible for transporting the
workpieces between the modules. In contrast to the modules, the AGV is
supplied with power by a battery

● (Optional) two carrying cases for transporting and storing the base plates
and modules, the lane plates and the AGV

● A 24V power supply 11A

For supplying power to the modules.

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● A 9V charger
For supplying the charging station with the charging voltage for the battery
of the AGV.

● Additional accessories
o Nine empty workpiece carriers for the high-bay warehouse and three
empty workpiece carriers for the AGV.

o 24 workpieces in the three available colors red, white and blue.

Stickers are already attached to the workpieces, which will be
analyzed in the quality assurance.

o Five Ethernet cables to connect the module plates together.

o Six power cables to connect the module plates together.

5
Inspection for damage in transit
After you have carefully removed the AGV from its packaging, complete a visual
inspection to determine whether components have come loose or been damaged
during transit. The following section provides instructions for how to inspect the
system for damage sustained in transit, and what to do if you find damage.

Box:

inspect the outer box for visible damage such as dents, holes or tears.

Loose parts:

Check whether loose parts are lying inside the box that may have come loose
during transportation. If necessary, return loose components to the correct
positions.

Loose cables:

Inspect all included cables for damage and check to ensure they are attached
securely. Check to ensure all hoses are connected.

Documenting damage:

● Take photographs of all damage found.

● Note down details like the type and scope of damage.

● Contact customer service:

Report damages found promptly to our service department. Send photos and your
notes regarding the damage as an attachment to your email.

fischertechnik GmbH

Klaus-Fischer-Str. 1

72178 Waldachtal

Germany

Phone: +49 74 43/12-43 69

Fax: +49 74 43/12-45 91

info@fischertechnik.de

www.fischertechnik.de

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Storing the packaging

● Store all packaging materials and damaged parts until your case has been
clarified.

● If you find serious damage, do not operate the product, in order to avoid
further damages.

Please pardon us for any inconvenience – we will do everything in our power to

replace or repair damaged or faulty parts as quickly as possible. If you have
questions regarding the inspection for damage in transit, or if you need support,
our customer service department will be happy to assist you at any time.

Available documentation
We provide you with extensive documentation to make it as easy and convenient
as possible for you to get started with and use the APS. This documentation helps
familiarize you with the product, clarify any questions which may come up, and
support you in commissioning and operation.

The documentation components are available online in different formats, and are
updated regularly to ensure you always have access to the latest information and
instructions. This allows you to access the documents you need anytime and from
anywhere, and thereby get the most out of your system.

The documentation available online covers:

● Setup and commissioning of the Agile Production Simulation

● Commissioning the Agile Production Simulation with the fischertechnik

Cloud

● Technical product details

● Calibrating the Agile Production Simulation

● Programming tasks for PLC development

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The corresponding documents are available in different languages at the following
link:

https://www.fischertechnik.de/e-learning/agile-production-simulation

We recommend familiarizing yourself with the available documentation in order to

ensure a smooth commissioning process and fault-free operation. If you have
further questions or need specific information, do not delay to contact our
customer service department.

Important notes
● Please store this manual for later reference.

● Switch off the system when it is not in use in order to save energy and
extend the service lives of your components.

We wish you much success with the Agile Product Simulation! If you have
questions or concerns, our customer service department would be happy to assist
you.

8
Setup and commissioning of the Agile Production
Simulation
Supporting you right from the start is important to us – from the moment you
open your product, to the moment you successfully produce your first workpiece.

With this “Setup and commissioning” documentation, we want to provide you with
a clear and easy to understand guide. Step by step, we will go through all necessary
processes and actions together, in order to ensure your product is set up optimally.

Structure of the Agile Production Simulation

Before we move on to the actual commissioning of your system, we will begin with
the essential step of physical setup. This includes, in particular, connecting and
combining the base plates and carefully wiring them together.

In a successful setup, all of the plates in the APS are securely connected to one
another. When the programs start on the individual modules, this indicates that
this process is complete. Only when they run smoothly can we be certain that the
physical setup was completed correctly and in full.

1. Physically connecting base plates

We recommend positioning the base plates according to the enclosed layout so

that your system is ready to use directly and without additional configuration.
Ensure that all modules are placed correctly.

You can tell they are positioned correctly because all tracks will either end on the
modules or have open ends intended for potential expansion of the APS. The base
area on which the AGV travels must be flat. We recommend setting up the entire
system on a flat surface like a large table. A flat surface of at least 184 cm x 129 cm is
required for the AGV set up according to the following layout.

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The standard setup is shown in the following layout. The plates are each connected
physically by pins, to that they fit together like puzzle pieces and cannot slide apart.

2. Electrically connecting base plates

The goal is to connect each base plate with the enclosed power and Ethernet
cables. Both the power and network connections are looped through the modules.
Ensure that you do not complete the wiring in a circuit.

Start with the power connection of the 24 V power supply to the charging station's
connection board. You can temporarily plug the 24 V power supply into the outlet
in order to test the connection board. The green LED on the connection board
indicates that the 24 V power supply was connected successfully.

Before continuing with the next steps, disconnect the 24 V power supply once
again as a safety measure, to ensure that it is not connected to power when wiring
the modules.

Connect the 9 V power supply (charger) to the charging module. Then you can
connect the Ethernet cable and power cable to the connection board. These are
used to connect the connection boards with the other modules.

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Ensure that all cables are securely connected to the connection boards. Then plug
the 24 V power supply and 9 V power supply into an outlet and use the following
description with LED 1 and LED 2 to ensure the modules are supplied correctly with
power.

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LED 1 on the connection boards of the other modules indicates the power supply
status:

● Green means that the 24V power supply is connected successfully.

● Red means that it is connected with reverse polarity.

In addition, there are two buttons with LED 2 on each connection board to the
power supply. These are used as an emergency stop for the individual module.

● LED 2 will be illuminated blue when the power supply has been completed
successfully.
● Red button: Triggers the emergency stop, interrupts the power supply to the
PLC and LED 2 is illuminated red.
● Blue button: The blue button must be pressed to restore the power supply.
LED 2 will be illuminated blue once again.

The following is an image showing what the connection board looks like when it is
fully connected.

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All modules, the router and Raspberry Pi will start up automatically when the
power supply is active; the necessary programs are pre-installed.

When the power supply is complete, the status LEDs will be illuminated on the top
of the PLC. On the TXT 4.0 controllers, the screen will be illuminated and show the
start screen.

The following is an overall image of the APS as it looks when it is wired fully.

This setup is saved in the central controller as the standard layout, and is also
mapped digitally in the application.

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3. Check the start-up of module applications

Most digital components of the APS will start automatically once the power supply
has been completed:

● The pre-installed PLC programs.

● All programs on the Raspberry Pi, in particular the central APS controller.

● The router to setup the wireless network.

If a program must be manually restarted, this can be triggered by interrupting and

then restoring the power supply.

The programs are already pre-selected on all four TXT 4.0 controllers and can be
started by pressing the touch screen.
After a successful start:

● A module-specific interface will be visible on the TXT 4.0 controllers. The

program can be ended by pressing “Stop program” on the bottom edge of
the screen. The green indicator beside “CONNECTED” indicates that the

14
 controller is connected to the central control unit.

● The status LED beside the “RUN/STOP” lettering on each PLC is green.

Before continuing with setup of the AGV, place the included black workpiece
carrier into the high-bay warehouse. The high-bay warehouse has a total of nine
storage spaces for it. Ensure that the groove points forward, so the workpiece
carrier can be removed and placed inside reliably by the robot.

4. Start the Automated Guided Vehicle (AGV)

The AGV also has three storage spaces for workpieces. As in the high bay
warehouse, three workpiece carriers must also be inserted there so that the
workpieces can be transported securely.

15
The power supply for the AGV is provided by the fischertechnik battery included in
the scope of delivery. It is delivered already charged up, so you can start the AGV
directly.

The AGV can be started by pressing the “ON/OFF” button. As with the modules, the
AGV also loads the right program automatically and can be started using the touch
screen.

If the battery charge status is too low to start the program, you can also charge it
with the APS charging station or directly via the enclosed 9 V charger.

1. With the charging station of the APS:

Please note that the APS must not be in operation. The charger must be plugged
into the charging station and into a socket. The circuit board in the charging
station must be connected to 24V and the 24V power supply unit must also be
connected to the socket. If the TXT 4.0 on the AGV is still on, switch it off via
"ON/OFF". Place the AGV in the charging station of the APS by hand so that the
charging contacts are connected to the contacts on the AGV. The battery is
charged when the red LED on the 9V charger and the LED in the charging
electronics on the AGV flash. When the battery is fully charged, the red LED on the
9V charger stops flashing and lights up continuously.

2. With the 9 V charger:

To do so, you must remove the battery from the AGV and connect the charging
cable directly.

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17
When the battery is fully charged, the red LED on the 9V charger stops flashing
and lights up continuously.

5. Starting the user interface for control and configuration

Once the incoming/outgoing goods module is supplied with power, the Raspberry
Pi placed there that handles central control of the APS also starts up. The router
that sets up the entire network of the SPS is also located there. No internet
connection is required for initial commissioning of the APS. The connection to the
fischertechnik Cloud is described separately in the “Commissioning with the
fischertechnik Cloud” section.

The central controller consists of a server component that runs in the background.
It monitors and controls all states of the entire APS. The central controller also
offers a user interface with which you can interact.

To access the user interface, you must connect to the router network (WiFi) using a
browser-capable device of your choice (such as a laptop or a tablet). The name of

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the network (SSID) and password generated for your APS are shown on the side of
the incoming / outgoing goods sensor station.

Once you are successfully connected to the network, access the address
192.168.0.100 in your browser. The following interface will load (http://192.168.0.100).
This interface contains all of the functions available for operating, monitoring, and
configuring the APS.

Click “Module” to navigate to the module overview.

The setup was successful if all six modules on the base plate and the AGV are
displayed in the list. The “Connected” column shows the current connection status
between the respective module and central controller.

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All modules are set up and networked. In the following section “Commissioning
with a local application,” the configuration is checked and the APS is set to active,
so that the first workpiece can be stored and produced. As described in the next
section, the Reset button at the top right of the interface is the best way to correct
initial connection problems.

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Commissioning with a local application
After the physical setup has been completed successfully, there are some final
steps to complete. Commissioning of the APS includes the configuration, and
concrete instructions for how to produce a workpiece.

1. Check the module connection status

Navigate to the “Module” menu. A list of connected modules will appear. All six
products included in the scope of delivery will be listed. The icon in the
“Connected” column indicates whether an active connection has been completed
between the central controller and corresponding module. If a module is not
shown as connected, the following actions may be helpful:

● Check the wiring of the module and correct accordingly if a power or

network cable has come loose.
● Resetting the APS: The “Reset” button is always at the top right of the user
interface (see the screen shot) and resets the APS to its initial state. This
means that all active orders will be removed and the connections between
the central controller and all modules will be newly formed. The stock in the
high-bay warehouse can also optionally be reset if there are any problems
(for instance, if a workpiece is lost).

This view also offers the possibility of calibrating modules. Module-specific positions
and distances are set in this process. The APS is delivered pre-calibrated; however,
the modules may be moved during setup and disassembly. If a module no longer
grips the workpiece precisely, you can correct this via the calibration. Instructions
for doing so are found at the following link:

https://www.fischertechnik.de/e-learning/agile-production-simulation

2. Check the layout of the module

21
The APS is pre-configured and delivered with a standard layout. The layout of the
APS defines where each module is located, and is the digital representation of the
physical structure. The user interface is located under the “Configuration” menu
item.

The standard layout can be maintained for commissioning. Check once again to
ensure you have arranged all modules correctly, so that all tracks and modules are
correctly arranged.

You can experiment with different layouts as you continue using the modules, by
rearranging them via drag & drop and saving the changes, so that the digital map
reflects the physical placement of the modules. This function is blocked if there is
an active production order in the APS. The previously mentioned Reset button can
be used to reset the APS to the initial state and make changes to the configuration.

3. Defining production processes for the three different workpieces

The production steps necessary to process the workpieces can be configured

individually depending on their color.

Each color has a mandatory processing station (drilling and/or milling) and
optional stations like AI quality assurance.

The default settings can be maintained for commissioning. Here as well, you can
make changes to the APS via drag & drop without programming knowledge,
similar to reconfiguring the layout.

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4. Positioning the Automated Guided Vehicle in the APS

In order to determine the initial position of the AGV, place the AGV in front of the
incoming/outgoing goods module, with the camera of the AGV pointed toward the
module. You can dock the AGV to the module using the “Module” interface you are
already familiar with. Click the “Dock to DPS” button to make the AGV start up and
dock to the module.

This action is also required after restarting or resetting the APS.

Once the AGV is successfully docked, you can send it to the charging station by
clicking the “Charge” button. The AGV should be fully charged before continuing
with commissioning.

The charging process will end automatically when the charger detects that the
battery is fully charged. Alternatively, you can end the charging process
prematurely via the “End charging” button. The AGV will move to a free module to
clear the charging station once again.

5. Delivering raw materials

Raw materials are delivered by inserting a workpiece into the incoming goods at
the incoming / outgoing goods station, shown here on the left side of the image.

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There are three different colors that can be produced by the APS. Stickers are
attached for each color that are detected as OK or NOK (not OK) by the quality
assurance.

There are 3 IO components:

OK or PASSED indicates that

the component is OK.
NOK or FAILED indicates that
the component is not OK.

3x white with drill hole

3x red with two milling pockets

3x blue with two milling pockets and drill hole

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There are 5 NIO components per color:

White:

With oval drill hole

With drill hole and one milling pocket

With crack

With one milling pocket

With drill hole and crack

Red:

With drill hole and two milling pockets

With drill hole and one milling pocket

With crack

With one milling pocket

With two milling pockets and crack

Blue:

With two milling pockets

With drill hole and one milling pocket

With crack

With one milling pocket

With two milling pockets, drill hole and crack

Once the light barrier is interrupted, the module will pick up the workpiece with
the gripper and classify it. This includes using the RGB sensor to determine the
color and reading out the NFC chip attached inside the workpiece.

25
We recommend using a blue workpiece with the following print (OK – no error
pattern) for initial production.

This workpiece is drilled and milled in the standard configuration, as well as

checked for defects in the quality assurance. Therefore, by producing this
workpiece you can directly test all assembled modules.

Do not forget to end the charging process for the AGV if it is still in the charging
station.

Delivery of raw materials is completed once the workpiece

● has been analyzed by incoming goods. This includes:

o Determining the color of the workpiece.

o Write the current storage date on the NFC tag in the workpiece.

● transported by the AGV to the high bay warehouse.

● stored in the high bay warehouse.

● displayed in the “Overview interface as stock.

6. Triggering an order

After successfully storing the raw material, it will be available for order.

To do so, switch to the “Overview” user interface. There, you will find a variety of
information about the APS, including the stock level, measurement data for the
sensor station, the camera image for the module and the order view.

You can click “Order” to trigger the production order, which will move the modules
to process the workpiece in sequence according to your configuration, and then
remove the workpiece from storage once again.

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All current production orders are displayed in the “Orders” menu during the APS
run time. This includes the following information, among other things:

● Order number (generated automatically by the central controller)

● Order start and current status
● All manufacturing steps required to produce the workpiece.
● The module on which the order is currently being carried out.

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A detailed list of individual production steps is shown under the “Production steps”
heading in the image above. The blue workpiece is

1. Removed from the high bay warehouse.

2. Milled on the milling station.

3. Drilled on the drilling station.

4. Checked for detects at quality assurance.

5. Removed from storage at outgoing goods once the quality inspection has
been completed successfully.

Each processing on a module runs according to the same pattern:

1. Workpiece is transported to the module by the AGV and unloaded there.

2. Workpiece is processed, stored or inspected by the module.

3. Workpiece is loaded back on the AGV and transported to the next step.

When the workpiece is delivered to outgoing goods, the first production order is
complete. The current order is removed from the view and is available for further
analysis under the “Simulation game” menu.

If production is not carried out to the end, there may be different reasons for this:

● The AGV loses the track, for instance due to external influences.
● A model is set to error state, indicated by an error message on the TXT
controller of the module or the red LED on incoming / outgoing goods.

Use the Reset button in the interface to set the APS back into an operable state.
Existing orders will be deleted so that production can restart with a new status.

The “Simulation game” view contains an analysis of the OEE indicator (Overall
Equipment Effectiveness) for all production orders. This applies both to production
orders completed in normal APS operations and to simulation games that can be
launched in this view.

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The simulation game can then be started by completing the following steps:

1. Prepare the APS: To start the simulation game, there must be workpieces in
the storage. These can be added by the usual storage process at incoming
goods. All modules must also be connected and ready.
2. Configure the simulation game: Additional workpieces from the storage can
be added to the simulation game using Add workpiece. The interface will
validate the set configuration, so that only valid simulation games can be
started.
3. Click “Start simulation game” to create the set configuration in the APS as
an order and start production.
4. Analyze the simulation game: After the last production step, the
productivity of the APS can be analyzed using the calculated indicator OEE
and changes can be made to improve it.

The following formulas are used in the APS simulation game to calculate the
indicator OEE:

OEE = Performance * Availability * Quality

Example: Performance is 80%, Availability is 100%, and Quality is 67%

OEE = 0.8 * 1.0 * 0.67 = 0.536 = 53.6%

Performance = Total planned production time / measured production time

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Example: A 200 second production time is configured for red and 400 seconds for
blue as the planned value. Total production will take 700 seconds to successfully
complete both orders.

Performance = (200 + 400) / 700 ~ 0.86

Availability = Total time from the start of the order to the end / time in production
or transportation steps.

Example: Production will start and continue for a total of 100 seconds, followed by
50 seconds of transportation. 200 seconds will pass before the last order is
complete.

Availability = 100 + 50 / 200 = 0.75

Quality = Number of successful orders / total number of orders

Example: 3 orders are included in the simulation game; 1 workpiece is sorted out by
quality assurance.

Quality = 2 / 3 ~ 0.67

Remarks:

● When calculating availability, small pauses (less than 500ms) between the
end of one step and start of the next step are ignored. System-related delays
are, therefore, not included in the processing and 100% availability is
possible.

● When calculating availability, the start time is the time the “ReceivedAt”
order is received after the order starts. The APS assumes that all modules are
ready for operation at the start of the simulation game.

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Commissioning with fischertechnik Cloud
Networking the APS with the fischertechnik Cloud makes it possible to control,
monitor and optimize production processes via the Internet. Setting up this
connection is explained in four steps below.

The fischertechnik Cloud is available at the following URL

https://www.fischertechnik-cloud.com

1. Connecting the router to an Internet connection

Before the APS can communicate with the cloud, it must be ensured that the local
network of the APS is connected to the internet. This is achieved by connecting the
router to an external internet source.

Make sure that you are connected to the APS network. Use your browser to
navigate to the address http://192.168.0.1/. The following login screen for the travel
router installed on the APS will appear. You can log in there with the default
password "admin1".

Carry out the "Quick setup"

1. The password for the network should not be changed, otherwise it must also
be changed on all components of the APS
2. Select "Dynamic IP" as an option for the WAN connection
3. The client settings and the wireless password of the external network can be
found on the configuration pages of your WLAN access point or requested
from your network administrator.
4. Confirm and exit setup
5. Verify the Internet connection by accessing the fischertechnik Cloud from
your end device: https://www.fischertechnik-cloud.com Make sure
that your end device is not connected to any networks other than the APS.

If you require further information, you can find this in the router documentation:

AC750 Wi-Fi Travel Router - Model No. TL-WR902AC

31
https://www.tp-link.com/us/user-guides/tl-wr902ac_v3/

2. registration in the fischertechnik Cloud

To be able to use the service, you must register. To do this, go to
www.fischertechnik-cloud.com. It is best to use "Firefox" or "Google Chrome" as
your Internet browser.

The following screen appears.

Select "Register now" to create your personal account. Fill in all the fields and
confirm your registration by clicking the "Register now" button.

After registering, you must confirm your e-mail address, then you can log in with
your user name and password. You can now use your account to access the
fischertechnik Cloud. The next step is to connect your APS to your Cloud account
so that data can actually be synchronized.

3. coupling the APS with the fischertechnik Cloud

On the Incoming/outgoing goods module contains another TXT controller. This is
the heart of the connection between the APS and the fischertechnik Cloud and is
referred to below as the gateway. After coupling, direct communication with the
cloud is possible via this, the controller serves as a gateway between the data
transfer within the APS network and the Internet. To set up the connection, the
APS program must be closed if it has already been started in a previous step.

Connect the TXT controller to the fischertechnik Cloud using the following menu
items on the touchscreen of the TXT 4.0 controller

"Settings - fischertechnik Cloud - New coupling".

If the TXT Controller can establish a connection with the cloud, a QR code and a
pairing code will appear. You now have 30 minutes to add the TXT Controller to

32
your account in the cloud. After this time has elapsed, you must start the pairing
process again.

You can scan the QR code, e.g. with the "Quick Scan" app, and you will
automatically be directed to the fischertechnik cloud.

Alternatively, you can go to "Settings - Add controller" on the fischertechnik cloud

page and enter the pairing code there manually. Here you can enter any name for
the TXT controller, e.g. its ID "TXT-7133".

Select the "Agile Production Simulation" module.

If pairing is successful, this is indicated on the display with "Pairing successful!".

Under the "Settings" menu item in the left-hand navigation bar, you will find a list
of all controllers linked to your account.

4. triggering the first order process via the cloud

The interfaces for controlling and monitoring the APS are integrated in the
fischertechnik Cloud under the menu item "Agile Production Simulation". You are
already familiar with these interfaces from commissioning the APS with the local
application, but you can now also use the same actions via fischertechnik Cloud.

33
Programming tasks for PLC development
To solve the programming tasks, you will need previous knowledge of the
"Structured Text" programming language (ST or SCL) and how to use the TIA Portal
development environment.

The programming solutions provided have been created with the TIA Portal V18 for
a SIMATIC S7-1200 programmable logic controller with CPU1512SP.

Alternatively, other control systems with the appropriate software can also be used
here.

You can find an introduction to programming with the TIA Portal here at SIEMENS,
for example:

https://www.siemens.com/de/de/produkte/automatisierung/systeme/industrie/sps/
s7-1200.html

https://new.siemens.com/global/de/unternehmen/nachhaltigkeit/ausbildung/sce/l
ern-lehr-unterlagen/erweiterte-programmierung.html

Further information including the sample solution can be found at:

https://github.com/fischertechnik/Agile-Production-Simulation-24V

34
Task 1: Multiple milling
Focus: Understanding and adapting the program sequence and loading it onto
the PLC.

Objective: Instead of milling the workpiece only once as before, it should now be
milled twice. The milling machine stops for one second between the two milling
processes.

Task 2: Extend OPC UA interface

Focus: Values permanently defined in the program code can be configured via the
OPC UA interface to enable a more flexible response to production scenarios
without having to adapt the programming of the PLC.

Objective: The time between milling operations defined in task 1 can now be freely
defined via the OPC UA interface.

35
Technical documentation

Technical structure of APS

The overall product is made up of six individual modules. This modularity enables
flexible configuration and adaptation to specific requirements and processes.

The modules are technically equipped with different controllers. Both the TXT 4.0
controller and the S7-1200 PLC are used. This variety of controllers allows a wide
range of functionalities and the integration of various technical standards. The TXT
4.0 controllers communicate with the central controller via MQTT. An individual
OPC UA server is started on the PLC in each case.

The Raspberry Pi forms the heart of the system. This central unit runs the central
control software, which is responsible for managing the individual production
orders, among other things. This ensures efficient and centralized control of the
entire production process.

An MQTT broker and Node-RED are also executed on the Raspberry Pi. Node-RED
serves as a bridge that realizes the translation from OPC-UA to MQTT. The MQTT
broker is an essential system component that supports a publish/subscribe
architecture. In this architecture, messages can be published, which can then be
retrieved and processed by all authenticated participants in the network.

The network is managed via a tp-link router. This router enables both wired and
wireless network connections and thus ensures the connectivity of all system
components.

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A key aim of this setup is to be close to real production environments. Even in
reality, it is unlikely that all components will use the same technical standard. This
diversity reflects the real conditions in the industry. Particular emphasis is placed
on the integration of different technologies and standards in order to create the
most efficient and flexible production environment possible.

The APS also relies on industry-standard communication frameworks. Various

groups are continuously working on cross-manufacturer issues to enable the most
effective message transmission for defined modules. Communication with the
automated guided vehicle system (AGV) in particular is based on the VDA5050
standard.

An optional extension offers a connection to the fischertechnik Cloud. A gateway

on the TXT 4.0 controller of the incoming/outgoing goods department enables this
connection. Relevant messages in the local network of the APS are forwarded to
the cloud broker and processed and displayed by the fischertechnik cloud.

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