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6.2 Milling Station (MILL)

Overview

The Milling Station performs milling operations on workpieces. It can pick up workpieces from the AGV, perform milling operations, and return them to the AGV.

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

Supported Commands

Command Purpose Metadata Typical Duration
PICK Pick workpiece from AGV None ~3 seconds
MILL Perform milling operation duration (seconds) Configurable (default 5s)
DROP Return workpiece to AGV None ~3 seconds

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

Subscriptions (Module listens to):

  • module/v1/ff/<serial>/order - Production commands from CCU
  • module/v1/ff/<serial>/instantAction - Immediate commands (calibration, reset)

Publications (Module sends):

  • module/v1/ff/<serial>/state - Current state (~1Hz or on change)
  • module/v1/ff/<serial>/connection - ONLINE/OFFLINE status (retained + LWT)
  • module/v1/ff/<serial>/factsheet - Module capabilities (on startup)

Command Examples

Example 1: PICK Workpiece

Command (CCU → Module):

{
  "timestamp": "2024-12-08T10:30:00.000Z",
  "serialNumber": "MILL001",
  "orderId": "order-abc-123",
  "orderUpdateId": 1,
  "action": {
    "id": "pick-action-456",
    "command": "PICK"
  }
}

State Response (Module → CCU) during execution:

{
  "headerId": 42,
  "timestamp": "2024-12-08T10:30:01.000Z",
  "serialNumber": "MILL001",
  "type": "MILL",
  "orderId": "order-abc-123",
  "orderUpdateId": 1,
  "paused": false,
  "actionState": {
    "id": "pick-action-456",
    "timestamp": "2024-12-08T10:30:01.000Z",
    "state": "RUNNING",
    "command": "PICK"
  },
  "errors": [],
  "loads": []
}

State Response on completion:

{
  "headerId": 43,
  "timestamp": "2024-12-08T10:30:03.000Z",
  "serialNumber": "MILL001",
  "type": "MILL",
  "orderId": "order-abc-123",
  "orderUpdateId": 1,
  "paused": false,
  "actionState": {
    "id": "pick-action-456",
    "timestamp": "2024-12-08T10:30:03.000Z",
    "state": "FINISHED",
    "command": "PICK"
  },
  "errors": [],
  "loads": [
    {
      "loadId": null,
      "loadType": "WHITE",
      "loadPosition": "MODULE"
    }
  ]
}

Example 2: MILL Operation

Command (CCU → Module):

{
  "timestamp": "2024-12-08T10:30:05.000Z",
  "serialNumber": "MILL001",
  "orderId": "order-abc-123",
  "orderUpdateId": 2,
  "action": {
    "id": "mill-action-789",
    "command": "MILL",
    "metadata": {
      "duration": 8
    }
  }
}

State Updates:

Running state:

{
  "headerId": 44,
  "timestamp": "2024-12-08T10:30:06.000Z",
  "serialNumber": "MILL001",
  "type": "MILL",
  "orderId": "order-abc-123",
  "orderUpdateId": 2,
  "paused": false,
  "actionState": {
    "id": "mill-action-789",
    "timestamp": "2024-12-08T10:30:06.000Z",
    "state": "RUNNING",
    "command": "MILL"
  },
  "errors": [],
  "loads": [
    {
      "loadType": "WHITE",
      "loadPosition": "MODULE"
    }
  ]
}

Finished state (after 8 seconds):

{
  "headerId": 45,
  "timestamp": "2024-12-08T10:30:14.000Z",
  "serialNumber": "MILL001",
  "type": "MILL",
  "orderId": "order-abc-123",
  "orderUpdateId": 2,
  "paused": false,
  "actionState": {
    "id": "mill-action-789",
    "timestamp": "2024-12-08T10:30:14.000Z",
    "state": "FINISHED",
    "command": "MILL"
  },
  "errors": [],
  "loads": [
    {
      "loadType": "WHITE",
      "loadPosition": "MODULE"
    }
  ]
}

Example 3: DROP Workpiece

Command:

{
  "timestamp": "2024-12-08T10:30:16.000Z",
  "serialNumber": "MILL001",
  "orderId": "order-abc-123",
  "orderUpdateId": 3,
  "action": {
    "id": "drop-action-def",
    "command": "DROP"
  }
}

State on Completion:

{
  "headerId": 47,
  "timestamp": "2024-12-08T10:30:19.000Z",
  "serialNumber": "MILL001",
  "type": "MILL",
  "orderId": "order-abc-123",
  "orderUpdateId": 3,
  "paused": false,
  "actionState": {
    "id": "drop-action-def",
    "timestamp": "2024-12-08T10:30:19.000Z",
    "state": "FINISHED",
    "command": "DROP"
  },
  "errors": [],
  "loads": []
}

Hardware Details

PLC Connections

The MILL module uses a Siemens S7 PLC with the following I/O:

Inputs (Sensors):

  • Light barrier at entrance
  • Light barrier at processing position
  • Suction cup position sensors (inner/outer)
  • Encoder signals for motor feedback

Outputs (Actuators):

  • Conveyor belt motor (forward/reverse, PWM)
  • Suction cup motors (extend/retract, PWM)
  • Vacuum pump
  • Compressor
  • Milling motor

Error Scenarios

PICK_ERROR

Cause: No workpiece detected after PICK operation

State Message:

{
  "actionState": {
    "id": "pick-action-456",
    "state": "FAILED",
    "command": "PICK"
  },
  "errors": [
    {
      "errorType": "PICK_ERROR",
      "timestamp": "2024-12-08T10:30:05.000Z",
      "errorLevel": "FATAL",
      "errorReferences": [
        {
          "referenceKey": "sensor",
          "referenceValue": "no_workpiece_detected"
        }
      ]
    }
  ]
}

MILL_ERROR

Cause: Motor fault or timeout during milling

State Message:

{
  "actionState": {
    "id": "mill-action-789",
    "state": "FAILED",
    "command": "MILL"
  },
  "errors": [
    {
      "errorType": "MILL_ERROR",
      "timestamp": "2024-12-08T10:30:10.000Z",
      "errorLevel": "FATAL",
      "errorReferences": [
        {
          "referenceKey": "reason",
          "referenceValue": "motor_fault"
        }
      ]
    }
  ]
}

DROP_ERROR

Cause: Workpiece not released or AGV not detected

Complete Production Cycle Example

Full sequence for milling a workpiece:

sequenceDiagram
    participant AGV
    participant CCU
    participant MILL

    Note over AGV: 1. AGV docks at MILL001
    CCU->>MILL: 2. PICK command
    MILL->>CCU: 3. State: RUNNING
    MILL->>CCU: 4. State: FINISHED - Load detected
    CCU->>AGV: 5. clearLoadHandler
    CCU->>MILL: 6. MILL command - duration: 8s
    MILL->>CCU: 7. State: RUNNING
    Note over MILL: 8. 8 seconds of milling
    MILL->>CCU: 9. State: FINISHED
    CCU->>MILL: 10. DROP command
    MILL->>CCU: 11. State: RUNNING
    MILL->>CCU: 12. State: FINISHED - No load
    CCU->>AGV: 13. clearLoadHandler
    Note over AGV: 14. AGV drives to next station
Loading

Related Documentation

OPC UA Variables

Variable Name Description Type
model Model name STRING
stat__idle Status: System is idle BOOL
cmd__mill Command: Milling operation BOOL
cmd__pick Command: Pick operation BOOL
cmd__drop Command: Drop operation BOOL
stat__pickFinished Status: Pick process finished BOOL
stat__dropFinished Status: Drop process finished BOOL
stat__millFinished Status: Milling process finished BOOL
cmd__millDuration Command: Milling duration INT
stat__pickFailed Status: Pick process failed BOOL
stat__dropFailed Status: Drop process failed BOOL
stat__dropActive Status: Drop process active BOOL
stat__pickActive Status: Pick process active BOOL
stat__millActive Status: Milling process active BOOL
cal__processEndTime Calibration time for process end TIME
cal__vacuumReleaseTime Calibration time for vacuum release TIME
cal__gripperDownTime Calibration time for gripper down TIME
cal__preFaultCheckTime Calibration time before fault check TIME
version Versioning STRING
cal__midLightGateTime Calibration time to position the workpiece centrically in the light barrier TIME
cal__postMillingTime Calibration time after milling TIME
cal__vacuumGenerateTime Calibration time for vacuum generation by compressor TIME