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6.6 Delivery and Pickup Station (DPS)

Overview

The DPS (Delivery and Pickup Station) serves as the input/output point for the factory. It handles workpiece delivery to the factory and shipping of finished products. It includes an NFC reader/writer for workpiece tracking.

Module Type: DPS
Serial Number: Cleaned variant of the SPS serial number

Supported Commands

Command Purpose Metadata Use Case
DROP Deliver raw workpiece to factory StoreMetadata (type, workpieceId) Input new workpiece
PICK Ship finished workpiece DeliveryMetadata (history) Output completed product

⚠️ Note: DPS has inverted logic compared to other modules:

  • DROP = Input to factory (module "drops" a new workpiece onto AGV)
  • PICK = Output from factory (module "picks" finished workpiece from AGV for delivery)

Supported Instant Actions

Action Purpose Metadata Description
factsheetRequest Request module info None Triggers publication of factsheet message
reset Reset module None Return module to initial state
startCalibration Enter calibration mode None Switch operating mode to TEACHIN
stopCalibration Exit calibration mode None Switch operating mode to AUTOMATIC
setCalibrationValues Update calibration Calibration data Update internal position values

MQTT Topics

Standard module topics:

  • Subscribe: module/v1/ff/<serial>/order, module/v1/ff/<serial>/instantAction
  • Publish: module/v1/ff/<serial>/state, module/v1/ff/<serial>/connection, module/v1/ff/<serial>/factsheet

Command Examples

Example 1: DROP (Input Raw Workpiece)

Command:

{
  "timestamp": "2024-12-08T08:00:00.000Z",
  "serialNumber": "DPS001",
  "orderId": "order-input-123",
  "orderUpdateId": 1,
  "action": {
    "id": "drop-action-abc",
    "command": "DROP",
    "metadata": {
      "type": "WHITE",
      "workpieceId": "wp-12345"
    }
  }
}

Behavior:

  1. Module reads NFC tag (if present)
  2. Places workpiece on AGV loading bay
  3. Writes workpiece metadata to NFC
  4. Activates status LED (green)

State Response (Finished):

{
  "headerId": 10,
  "timestamp": "2024-12-08T08:00:03.000Z",
  "serialNumber": "DPS001",
  "type": "DPS",
  "orderId": "order-input-123",
  "orderUpdateId": 1,
  "paused": false,
  "actionState": {
    "id": "drop-action-abc",
    "timestamp": "2024-12-08T08:00:03.000Z",
    "state": "FINISHED",
    "command": "DROP"
  },
  "errors": [],
  "loads": []
}

Example 2: PICK (Output Finished Product)

Command:

{
  "timestamp": "2024-12-08T08:30:00.000Z",
  "serialNumber": "DPS001",
  "orderId": "order-output-456",
  "orderUpdateId": 1,
  "action": {
    "id": "pick-action-def",
    "command": "PICK",
    "metadata": {
      "workpiece": {
        "workpieceId": "wp-12345",
        "type": "WHITE",
        "state": "PROCESSED",
        "history": [
          {
            "ts": 1702028400,
            "code": 100
          },
          {
            "ts": 1702028460,
            "code": 600
          },
          {
            "ts": 1702028520,
            "code": 700
          },
          {
            "ts": 1702028580,
            "code": 200
          },
          {
            "ts": 1702028640,
            "code": 800
          }
        ]
      }
    }
  }
}

NFC Position Codes (from metadata.workpiece.history):

  • 100 - DPS DROP (Input)
  • 200 - AIQS CHECK_QUALITY
  • 300 - HBW PICK (Storage retrieval)
  • 400 - HBW DROP (Storage deposit)
  • 500 - OVEN FIRE
  • 600 - MILL MILL
  • 700 - DRILL DRILL
  • 800 - DPS PICK (Output)

Behavior:

  1. Module picks workpiece from AGV
  2. Writes complete history to NFC tag
  3. Outputs workpiece to delivery chute
  4. Activates status LED sequence

State Response (Finished):

{
  "headerId": 15,
  "timestamp": "2024-12-08T08:30:04.000Z",
  "serialNumber": "DPS001",
  "type": "DPS",
  "orderId": "order-output-456",
  "orderUpdateId": 1,
  "paused": false,
  "actionState": {
    "id": "pick-action-def",
    "timestamp": "2024-12-08T08:30:04.000Z",
    "state": "FINISHED",
    "command": "PICK"
  },
  "errors": [],
  "loads": [
    {
      "loadType": "WHITE",
      "loadPosition": "MODULE"
    }
  ]
}

NFC Functionality

Data Structure (JSON Representation)

When accessing via the standard module or internal NodeRed topics, the NFC data is abstracted as JSON:

{
  "workpieceId": "wp-12345",
  "type": "WHITE",
  "state": "PROCESSED",
  "history": [
    {"ts": 1702028400, "code": 100},
    {"ts": 1702028460, "code": 600},
    {"ts": 1702028520, "code": 700},
    {"ts": 1702028580, "code": 200},
    {"ts": 1702028640, "code": 800}
  ]
}

Raw Data Definition (Byte Map)

The NFC chip (NTAG213) memory map is defined as follows:

Byte Offset Content Description
0 NFC UID 7 bytes (NTAG213) or 4 bytes (Mifare)
7 Byte 0 State: 0=RAW, 1=PROCESSED, 2=REJECTED
8 Byte 1 Type: 0=NONE, 1=WHITE, 2=RED, 3=BLUE
9 Byte 2 Mask timestamps
10 Byte 3 Reserved
11 Byte 4..67 History: Array of 8 x int64 (8 bytes each)

History Code Mapping

The raw history codes stored on the chip map to the following stations:

Code Description Module
100 Input Raw Material DPS
300 Storage In HBW
400 Storage Out HBW
500 Processing Oven OVEN
600 Processing Mill MILL
601 Processing Drill DRILL
700 Quality Control AIQS
800 Dispatch Goods DPS

Low-Level Interface (Direct TXT Access)

This section describes the direct interface to the NFC reader on the internal TXT controller (topics starting with /j1/txt/...).

Topics:

Direction Topic Purpose
Subscribe /j1/txt/1/f/o/nfc/ds Send Read/Delete commands
Publish /j1/txt/1/f/i/nfc/ds Receive NFC content

Commands:

{
  "ts": "<timestamp>",
  "cmd": "<read/delete>"
}

Response Format (Read):

{
  "ts": 1683892857.208132,
  "history": [
    { "ts": 1682342421.8, "code": 100 },
    { "ts": 1682342283.1, "code": 300 }
  ],
  "workpiece": {
    "type": 0,
    "id": "041e9d7adb7281",
    "state": 0
  }
}

Response Format (Delete): Returns empty history.

{
  "ts": 1683892857.208132,
  "history": [],
  "workpiece": {
    "type": 0,
    "id": "041e9d7adb7281",
    "state": 0
  }
}

Hardware Details

PLC I/O

Inputs: Light barrier, NFC reader, camera for position detection
Outputs: Conveyor motors (PWM), status LEDs (RGB), NFC writer

Status LED Control

The DPS has RGB status LEDs that can be controlled via instant action:

Instant Action:

{
  "serialNumber": "DPS001",
  "timestamp": "2024-12-08T09:00:00.000Z",
  "actions": [
    {
      "actionType": "setStatusLED",
      "actionId": "led-123",
      "metadata": {
        "red": false,
        "yellow": false,
        "green": true
      }
    }
  ]
}

Calibration

The DPS supports calibration of:

  • Camera Position: X/Y coordinates for different stations
  • Color Sensor: RGB thresholds
  • Timing: Conveyor and NFC operation timings

Errors

  • DROP_ERROR - Failed to deliver workpiece (NFC write error, conveyor jam)
  • PICK_ERROR - Failed to retrieve workpiece (NFC read error, no workpiece detected)

Special Considerations

Command Logic

Unlike other modules where PICK takes from AGV and DROP places on AGV:

  • DPS DROP: Places NEW workpiece onto AGV (factory input)
  • DPS PICK: Takes FINISHED workpiece from AGV (factory output)

NFC Tag Management

  • Raw workpieces may not have NFC tags initially
  • Tags are written during DROP operation
  • Complete history is written during PICK operation
  • NFC data enables traceability and ROBO Pro Coding integration

Related Documentation

Internal Communication (Node-RED to TXT)

The DPS module uses an internal TXT controller specifically for controlling the robot arm (movement) and the NFC reader/writer. Other sensors (like the RGB color sensor and light barriers) are connected to the main 24V PLC. This controller communicates with the main Node-RED instance via MQTT.

Topic Structure

The internal communication uses the specific prefix NodeRed to identify the bridge: module/v1/ff/NodeRed/{DEVICEID}/...

Where {DEVICEID} is the 4-character ID of the internal TXT controller (e.g., from config.json).

Topics

Direction Topic Purpose
Subscribe module/v1/ff/NodeRed/{DEVICEID}/order Receive commands (INPUT_RGB, RGB_NFC, DROP, PICK)
Subscribe module/v1/ff/NodeRed/{DEVICEID}/instantAction Receive immediate commands (reset, announceOutput)
Publish module/v1/ff/NodeRed/{DEVICEID}/state Publish current status and action results

Internal Order Messages

Topic: module/v1/ff/NodeRed/{DEVICEID}/order

Supported Commands

  1. INPUT_RGB

    • Description: Move workpiece from input belt to RGB color sensor. (Note: RGB conversion happens on the 24V PLC side).
    • Result: None (Updates state).

  2. RGB_NFC

    • Description: Move from RGB sensor to NFC reader. Reads NFC ID.
    • Metadata: {'type': 'RED' | 'WHITE' | 'BLUE'} (Workpiece color).
    • Result: NFC ID.

  3. DROP

    • Description: Move from NFC reader to FTS (AGV).
    • Result: None.

  4. PICK

    • Description: Receive workpiece from FTS, write NFC data, and move to Output or NIO bin.
    • Metadata: {'workpiece': { 'history': ..., 'workpieceId': ..., 'type': ..., 'state': ...}} (NFC data to write).
    • Result: PASSED or FAILED (depending on NFC write success and target).

Example Order:

{
  "orderId": "SOME_ID",
  "orderUpdateId": 1,
  "timestamp": "2023-02-02T13:58:06Z",
  "action": {
    "command": "DROP",
    "id": "ID#2",
    "metadata": {
      "type": "WHITE"
    }
  }
}

Internal State Messages

Topic: module/v1/ff/NodeRed/{DEVICEID}/state

{
  "orderId": "SOME_ID",
  "orderUpdateId": 1,
  "timestamp": "2023-02-02T13:57:06Z",
  "action": {
    "command": "DROP",
    "id": "ID#1",
    "metadata": {
      "result": null
    }
  }
}

Internal Instant Actions

Topic: module/v1/ff/NodeRed/{DEVICEID}/instantAction

Supported Actions

  • factsheetRequest: Publishes to .../factsheet.
  • reset: Resets module to known idle state.
  • announceOutput: Announces intent to output. Aborts current input, changes orderId, resets orderUpdateId.
  • startCalibration, testCalibrationPosition, stopCalibration, etc.

example announceOutput:

{
   "serialNumber": "serial",
   "timestamp":"2022-03-03T12:12:12Z",
   "actions":[
      {
         "actionType": "announceOutput",
         "actionId": "3234567890abcdee",
         "metadata": {
          "orderId": "NEW_ORDER_ID"
         }
      }
   ]
}

Internal State Machine

The internal controller follows this state logic:

State Description Transitions To
STATE_IDLE Waiting for workpiece STATE_INPUT_RUNNING, STATE_PICK_NFC_RUNNING
STATE_INPUT_RUNNING Processing input STATE_RGB_IDLE
STATE_RGB_IDLE Waiting for recognition STATE_RGB_NFC_RUNNING
STATE_RGB_NFC_RUNNING Moving to NFC STATE_NFC_IDLE
STATE_NFC_IDLE Waiting for decision STATE_DROP_RUNNING
STATE_DROP_RUNNING Loading to AGV STATE_IDLE
STATE_PICK_NFC_RUNNING Unloading from AGV STATE_IDLE (via Reset)

Internal Action Mappings:

  • INPUT_RGB → STATE_INPUT_RUNNING
  • RGB_NFC → STATE_RGB_NFC_RUNNING
  • DROP → STATE_DROP_RUNNING
  • PICK → STATE_PICK_NFC_RUNNING

OPC UA Variables

Variable Name Description Type
cal__colorBlueSetpoint Setpoint for blue color in calibration INT
cal__colorWhiteSetpoint Setpoint for white color in calibration INT
cal__shortProcessWaitTime Short waiting time during process TIME
cal__colorValue Color value (live) INT
stat__input Input status BOOL
stat__output Output status BOOL
cal__colorRange Color range in calibration INT
stat__colorRangeRed Status: Red color range BOOL
stat__colorRangeWhite Status: White color range BOOL
stat__colorRangeBlue Status: Blue color range BOOL
version Versioning STRING
cmd__calibDefault Command: Reset to factory settings BOOL
stat__calibDefaultFinished Status: Reset to factory settings finished BOOL
cal__parkPosX Park position in X direction for calibration DINT
cal__parkPosY Park position in Y direction for calibration DINT
cmd__park Command: Park BOOL
stat__parkActive Status: Park active BOOL
cal__defUpperLimitX Default upper limit in X direction DINT
cal__defLowerLimitX Default lower limit in X direction DINT
cal__defUpperLimitY Default upper limit in Y direction DINT
cal__defLowerLimitY Default lower limit in Y direction DINT
cal__defHomePosX Default home position in X direction DINT
cal__defHomePosY Default home position in Y direction DINT
cal__defCustomPosX Default custom position in X direction DINT
cal__defCustomPosY Default custom position in Y direction DINT
cal__defColorRedSetpoint Default setpoint for red color in calibration INT
cal__defColorBlueSetpoint Default setpoint for blue color in calibration INT
cal__defColorWhiteSetpoint Default setpoint for white color in calibration INT
cal__defColorRange Default color range in calibration INT
cal__defShortProcessWaitTime Default short waiting time during process TIME