ABB Automation Builder for Material Handling
Automation Builder provides ABB's unified environment for AC500 PLC programming, drive configuration, and HMI development. Built on CODESYS V3 with ABB-specific enhancements. Strength lies in seamless drive integration with ACS880 and other families....
Platform Strengths for Material Handling:
- Excellent for robotics integration
- Strong in power and utilities
- Robust hardware for harsh environments
- Good scalability
Unique ${brand.software} Features:
- Integrated drive configuration for ACS880, ACS580 drives
- Extensive application libraries: HVAC, pumping, conveying, crane control
- Safety programming for AC500-S within standard project
- Panel Builder 600 HMI development integrated
Key Capabilities:
The Automation Builder environment excels at Material Handling applications through its excellent for robotics integration. This is particularly valuable when working with the 5 sensor types typically found in Material Handling systems, including Laser scanners, RFID readers, Barcode scanners.
Control Equipment for Material Handling:
- Automated storage and retrieval systems (AS/RS)
- Automated guided vehicles (AGVs/AMRs)
- Vertical lift modules (VLMs)
- Carousel systems (horizontal and vertical)
ABB's controller families for Material Handling include:
- AC500: Suitable for intermediate to advanced Material Handling applications
- AC500-eCo: Suitable for intermediate to advanced Material Handling applications
- AC500-S: Suitable for intermediate to advanced Material Handling applications
Hardware Selection Guidance:
PM554 entry-level for simple applications. PM564 mid-range for OEM machines. PM573 high-performance for complex algorithms. PM5 series latest generation with cloud connectivity. AC500-S for integrated safety....
Industry Recognition:
Medium - Strong in power generation, mining, and marine applications. AC500 coordinating VFD-controlled motors with ACS880 drives. Energy optimization reducing consumption 25-40%. Robot integration via ABB robot interfaces. Press line automation with AC500-S safety....
Investment Considerations:
With $$ pricing, ABB positions itself in the mid-range segment. For Material Handling projects requiring advanced skill levels and 4-12 weeks development time, the total investment includes hardware, software licensing, training, and ongoing support.
Understanding Function Blocks for Material Handling
Function Block Diagram (FBD) is a graphical programming language where functions and function blocks are represented as boxes connected by signal lines. Data flows from left to right through the network.
Execution Model:
Blocks execute based on data dependencies - a block executes only when all its inputs are available. Networks execute top to bottom when dependencies allow.
Core Advantages for Material Handling:
- Visual representation of signal flow: Critical for Material Handling when handling intermediate to advanced control logic
- Good for modular programming: Critical for Material Handling when handling intermediate to advanced control logic
- Reusable components: Critical for Material Handling when handling intermediate to advanced control logic
- Excellent for process control: Critical for Material Handling when handling intermediate to advanced control logic
- Good for continuous operations: Critical for Material Handling when handling intermediate to advanced control logic
Why Function Blocks Fits Material Handling:
Material Handling systems in Logistics & Warehousing typically involve:
- Sensors: Barcode scanners for product/location identification, RFID readers for pallet and container tracking, Photoelectric sensors for load presence detection
- Actuators: Conveyor motors and drives, Crane bridge, hoist, and trolley drives, Shuttle car drives
- Complexity: Intermediate to Advanced with challenges including Maintaining inventory accuracy in real-time
Programming Fundamentals in Function Blocks:
StandardBlocks:
- logic: AND, OR, XOR, NOT - Boolean logic operations
- comparison: EQ, NE, LT, GT, LE, GE - Compare values
- math: ADD, SUB, MUL, DIV, MOD - Arithmetic operations
TimersCounters:
- ton: Timer On-Delay - Output turns ON after preset time
- tof: Timer Off-Delay - Output turns OFF after preset time
- tp: Pulse Timer - Output pulses for preset time
Connections:
- wires: Connect output pins to input pins to pass data
- branches: One output can connect to multiple inputs
- feedback: Outputs can feed back to inputs for state machines
Best Practices for Function Blocks:
- Arrange blocks for clear left-to-right data flow
- Use consistent spacing and alignment for readability
- Label all inputs and outputs with meaningful names
- Create custom FBs for frequently repeated logic patterns
- Minimize wire crossings by careful block placement
Common Mistakes to Avoid:
- Creating feedback loops without proper initialization
- Connecting incompatible data types
- Not considering execution order dependencies
- Overcrowding networks making them hard to read
Typical Applications:
1. HVAC control: Directly applicable to Material Handling
2. Temperature control: Related control patterns
3. Flow control: Related control patterns
4. Batch processing: Related control patterns
Understanding these fundamentals prepares you to implement effective Function Blocks solutions for Material Handling using ABB Automation Builder.
Implementing Material Handling with Function Blocks
Material handling automation uses PLCs to control the movement, storage, and retrieval of materials in warehouses, distribution centers, and manufacturing facilities. These systems optimize storage density, picking efficiency, and inventory accuracy.
This walkthrough demonstrates practical implementation using ABB Automation Builder and Function Blocks programming.
System Requirements:
A typical Material Handling implementation includes:
Input Devices (Sensors):
1. Barcode scanners for product/location identification: Critical for monitoring system state
2. RFID readers for pallet and container tracking: Critical for monitoring system state
3. Photoelectric sensors for load presence detection: Critical for monitoring system state
4. Height and dimension sensors for load verification: Critical for monitoring system state
5. Position encoders for crane and shuttle systems: Critical for monitoring system state
Output Devices (Actuators):
1. Conveyor motors and drives: Primary control output
2. Crane bridge, hoist, and trolley drives: Supporting control function
3. Shuttle car drives: Supporting control function
4. Fork positioning and load handling: Supporting control function
5. Vertical lift mechanisms: Supporting control function
Control Equipment:
- Automated storage and retrieval systems (AS/RS)
- Automated guided vehicles (AGVs/AMRs)
- Vertical lift modules (VLMs)
- Carousel systems (horizontal and vertical)
Control Strategies for Material Handling:
1. Primary Control: Automated material movement using PLCs for warehouse automation, AGVs, and logistics systems.
2. Safety Interlocks: Preventing Route optimization
3. Error Recovery: Handling Traffic management
Implementation Steps:
Step 1: Map all storage locations with addressing scheme
In Automation Builder, map all storage locations with addressing scheme.
Step 2: Define product characteristics (size, weight, handling requirements)
In Automation Builder, define product characteristics (size, weight, handling requirements).
Step 3: Implement location tracking database interface
In Automation Builder, implement location tracking database interface.
Step 4: Program crane/shuttle motion control with positioning
In Automation Builder, program crane/shuttle motion control with positioning.
Step 5: Add load verification (presence, dimension, weight)
In Automation Builder, add load verification (presence, dimension, weight).
Step 6: Implement WMS interface for task assignment
In Automation Builder, implement wms interface for task assignment.
ABB Function Design:
Standard FB structure with VAR_INPUT/OUTPUT/VAR. Methods extend functionality. ABB application libraries provide tested FBs. Drive FBs wrap drive parameter access.
Common Challenges and Solutions:
1. Maintaining inventory accuracy in real-time
- Solution: Function Blocks addresses this through Visual representation of signal flow.
2. Handling damaged or misplaced loads
- Solution: Function Blocks addresses this through Good for modular programming.
3. Coordinating multiple cranes in same aisle
- Solution: Function Blocks addresses this through Reusable components.
4. Optimizing storage assignment dynamically
- Solution: Function Blocks addresses this through Excellent for process control.
Safety Considerations:
- Aisle entry protection with light curtains and interlocks
- Personnel detection in automated zones
- Safe positioning for maintenance access
- Overload protection for cranes and lifts
- Fire suppression system integration
Performance Metrics:
- Scan Time: Optimize for 5 inputs and 5 outputs
- Memory Usage: Efficient data structures for AC500 capabilities
- Response Time: Meeting Logistics & Warehousing requirements for Material Handling
ABB Diagnostic Tools:
Online monitoring with live values,Watch window with expressions,Breakpoints for inspection,Drive diagnostics showing fault history,Communication diagnostics for network statistics
ABB's Automation Builder provides tools for performance monitoring and optimization, essential for achieving the 4-12 weeks development timeline while maintaining code quality.
ABB Function Blocks Example for Material Handling
Complete working example demonstrating Function Blocks implementation for Material Handling using ABB Automation Builder. Follows ABB naming conventions. Tested on AC500 hardware.
(* ABB Automation Builder - Material Handling Control *)
(* Reusable Function Blocks Implementation *)
(* Standard FB structure with VAR_INPUT/OUTPUT/VAR. Methods ext *)
FUNCTION_BLOCK FB_MATERIAL_HANDLING_Controller
VAR_INPUT
bEnable : BOOL; (* Enable control *)
bReset : BOOL; (* Fault reset *)
rProcessValue : REAL; (* Barcode scanners for product/location identification *)
rSetpoint : REAL := 100.0; (* Target value *)
bEmergencyStop : BOOL; (* Safety input *)
END_VAR
VAR_OUTPUT
rControlOutput : REAL; (* Conveyor motors and drives *)
bRunning : BOOL; (* Process active *)
bComplete : BOOL; (* Cycle complete *)
bFault : BOOL; (* Fault status *)
nFaultCode : INT; (* Diagnostic code *)
END_VAR
VAR
(* Internal Function Blocks *)
fbSafety : FB_SafetyMonitor; (* Safety logic *)
fbRamp : FB_RampGenerator; (* Soft start/stop *)
fbPID : FB_PIDController; (* Process control *)
fbDiag : FB_Diagnostics; (* ST_Alarm structure with bActive, bAcknowledged, dtActivation, nCode, sMessage. Array of alarms with detection and acknowledgment logic. Integration with ABB alarm libraries. *)
(* Internal State *)
eInternalState : E_ControlState;
tonWatchdog : TON;
END_VAR
(* Safety Monitor - Aisle entry protection with light curtains and interlocks *)
fbSafety(
Enable := bEnable,
EmergencyStop := bEmergencyStop,
ProcessValue := rProcessValue,
HighLimit := rSetpoint * 1.2,
LowLimit := rSetpoint * 0.1
);
(* Main Control Logic *)
IF fbSafety.SafeToRun THEN
(* Ramp Generator - Prevents startup surge *)
fbRamp(
Enable := bEnable,
TargetValue := rSetpoint,
RampRate := 20.0, (* Logistics & Warehousing rate *)
CurrentValue => rSetpoint
);
(* PID Controller - Process regulation *)
fbPID(
Enable := fbRamp.InPosition,
ProcessValue := rProcessValue,
Setpoint := fbRamp.CurrentValue,
Kp := 1.0,
Ki := 0.1,
Kd := 0.05,
OutputMin := 0.0,
OutputMax := 100.0
);
rControlOutput := fbPID.Output;
bRunning := TRUE;
bFault := FALSE;
nFaultCode := 0;
ELSE
(* Safe State - Personnel detection in automated zones *)
rControlOutput := 0.0;
bRunning := FALSE;
bFault := NOT bEnable; (* Only fault if not intentional stop *)
nFaultCode := fbSafety.FaultCode;
END_IF;
(* Diagnostics - Circular buffer with ST_LogRecord. Write index with modulo wrap. Triggered capture with pre/post samples. File export using file system library. *)
fbDiag(
ProcessRunning := bRunning,
FaultActive := bFault,
ProcessValue := rProcessValue,
ControlOutput := rControlOutput
);
(* Watchdog - Detects frozen control *)
tonWatchdog(IN := bRunning AND NOT fbPID.OutputChanging, PT := T#10S);
IF tonWatchdog.Q THEN
bFault := TRUE;
nFaultCode := 99; (* Watchdog fault *)
END_IF;
(* Reset Logic *)
IF bReset AND NOT bEmergencyStop THEN
bFault := FALSE;
nFaultCode := 0;
fbDiag.ClearAlarms();
END_IF;
END_FUNCTION_BLOCKCode Explanation:
- 1.Encapsulated function block follows Standard FB structure with VAR_INPUT/OUT - reusable across Logistics & Warehousing projects
- 2.FB_SafetyMonitor provides Aisle entry protection with light curtains and interlocks including high/low limits
- 3.FB_RampGenerator prevents startup issues common in Material Handling systems
- 4.FB_PIDController tuned for Logistics & Warehousing: Kp=1.0, Ki=0.1
- 5.Watchdog timer detects frozen control - critical for intermediate to advanced Material Handling reliability
- 6.Diagnostic function block enables Circular buffer with ST_LogRecord. Write index with modulo wrap. Triggered capture with pre/post samples. File export using file system library. and ST_Alarm structure with bActive, bAcknowledged, dtActivation, nCode, sMessage. Array of alarms with detection and acknowledgment logic. Integration with ABB alarm libraries.
Best Practices
- ✓Follow ABB naming conventions: g_ prefix for globals. i_/q_ for FB I/O. Type prefixes: b=BOOL, n=INT, r=REAL, s
- ✓ABB function design: Standard FB structure with VAR_INPUT/OUTPUT/VAR. Methods extend functionality. A
- ✓Data organization: DUTs define structures. GVLs group related data. Retain attribute preserves vari
- ✓Function Blocks: Arrange blocks for clear left-to-right data flow
- ✓Function Blocks: Use consistent spacing and alignment for readability
- ✓Function Blocks: Label all inputs and outputs with meaningful names
- ✓Material Handling: Verify load presence before and after each move
- ✓Material Handling: Implement inventory checkpoints for reconciliation
- ✓Material Handling: Use location states to prevent double storage
- ✓Debug with Automation Builder: Use structured logging to controller log
- ✓Safety: Aisle entry protection with light curtains and interlocks
- ✓Use Automation Builder simulation tools to test Material Handling logic before deployment
Common Pitfalls to Avoid
- ⚠Function Blocks: Creating feedback loops without proper initialization
- ⚠Function Blocks: Connecting incompatible data types
- ⚠Function Blocks: Not considering execution order dependencies
- ⚠ABB common error: Exception 'AccessViolation': Null pointer access
- ⚠Material Handling: Maintaining inventory accuracy in real-time
- ⚠Material Handling: Handling damaged or misplaced loads
- ⚠Neglecting to validate Barcode scanners for product/location identification leads to control errors
- ⚠Insufficient comments make Function Blocks programs unmaintainable over time