Commissioning the Digital Machine

1 Content
2 Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 IT security and data protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5 Digital Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

6 System requirements/settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6.1 System Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6.2 Necessary Software Packages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6.3 Configuring Settings for Operation without D:\ Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6.4 Configuring OPC UA Server Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6.5 Settings for Operating the Cycle Time Assist and Part Counter Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7 Start the Digital Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7.1 Starting the Digital Machine with Batch Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7.2 Manually Starting the Digital Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7.3 Setting Up the Robots and Removing HMI Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7.4 Troubleshooting — TwinCAT Runtime. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

8 Service – Helpdesk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

9 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Foreword
This technical documentation is an integral part of the software. This document contains important information
regarding safety, application, parameterization and programming.
The document must be read and understood before application to eliminate potential errors and to ensure smooth
operation.
3 General Information
Explanation of Icons

Safety Icons and Signal Words Used

This documentation uses the following safety icons and signal words. They provide information about potential
hazards and include instructions on how to avoid these hazards.

Description of a high-risk hazard which, if disregarded, will lead to death or serious injury.
The consequences of the hazard are specified.
▪ Steps for preventing the hazard from occurring are specified.

Description of a medium-risk hazard which, if disregarded, may lead to death or serious

injury.
The consequences of the hazard are specified.
▪ Steps for preventing the hazard from occurring are specified.

Description of a low-risk to medium-risk hazard which, if disregarded, may lead to minor or

moderate injury.
The consequences of the hazard are specified.
▪ Steps for preventing the hazard from occurring are specified.

Description of a risk to property and the environment. The note excludes injuries.
The consequences of the hazard are specified.
▪ Steps for preventing the hazard from occurring are specified.

General Icons and Tags

In addition to the safety notices, the following information is formatted and tagged accordingly:

Information unit Description Example

Operating instruction Each operating instruction step is numbered. 1. In the File menu, click Open.
step

Interface text Text that has been extracted from the interface of 1. Click on the Parameter tab.
a software tool is shown in italics.

Code Programming examples for the structured text. Example of a code.

Result of an operating An arrow is used to show the result at the end of

instruction the operating instruction.
The object is parameterized.

Contains important information, references to other documents and/or tips and tricks.

Copyright
These instructions, including all diagrams and images contained herein, are protected by copyright. Any use of
these instructions that deviates from the copyright provisions is not permitted. Any reproduction, translation into
other languages, or electronic and photographic archiving and amendment requires written authorization from
Robert Bosch Manufacturing Solutions GmbH, Bosch Connected Industry (BCI), Stuttgart, Germany. Any violations
will incur claims for damages.
Robert Bosch Manufacturing Solutions GmbH reserves the right to make changes in accordance with technical
progress. All rights pertaining to patents or protection of utility patents are reserved by Robert Bosch
Manufacturing Solutions GmbH.
Microsoft, Excel, Word, Outlook and Windows are registered trademarks or brands of the Microsoft Corporation in
the USA and/or other countries. Other product or company names listed in this document may be protected
trademarks of their respective owners, or products may be subject to patent protection.

Disclaimer
This document has been produced taking into account the applicable standards and regulations, and according to
the latest technology. The content of the documentation has been checked for accuracy, but discrepancies may
still occur. No liability is assumed for these discrepancies. Changes and additions may be recorded in the next
version of the document. Robert Bosch Manufacturing Solutions GmbH assumes no liability for damages or
accidents that occur as a result of the following:
▪ Non-compliance with this document
▪ Use by untrained or unqualified personnel
▪ Use contrary to intended use
▪ Non-approved modification of the software/hardware
4 IT security and data protection
Intended use
The basic prerequisites required for using Nexeed Automation software products in compliance with
IT security are as follows:
▪ The software specified for operating the machine is not intended for operation on open networks or wireless
networks.
▪ Nexeed Automation software products are not intended for direct or unprotected operation on the Internet.
▪ Installations implemented using Nexeed Automation software products are not intended for operation in
public areas, i.e. they should not be accessible to the public.
To ensure safe operation of Nexeed Automation software products, the following measures must be taken:
▪ Continuous training of operating and maintenance personnel regarding IT security and current IT security
threats.
▪ The development of a suitable network zone concept. This includes network segmentation and controlled
data flow between zones.
▪ Installation of an authorization management system and secure administration. IT components accessed and
managed only by authorized personnel.
▪ Restrictive use of removable media and mobile devices.
If service is required:
▪ The operator must ensure that the internal and external service personnel with access to installations
implemented using Nexeed Automation software products have been trained according to the operator's IT
security guidelines.
Qualified personnel
All tasks and work listed must only be performed by qualified and authorized personnel.
▪ Nexeed Automation software products are designed to be operated by qualified personnel and maintained by
technical personnel with the appropriate IT security training.
Such personnel must work in accordance with an appropriate authorization and security management
system.

Data protection
The protection of personal data and compliance with legal requirements regarding data protection are important
to Robert Bosch Manufacturing Solutions GmbH.
As the developer of the Nexeed Automation software solution, we take the requirements of the General Data
Protection Regulation (GDPR) seriously and abide by them with our
products by providing the technical capability to implement data protection legislation. The technical possibilities
Nexeed Automation provides for this purpose can be found in the product documentation.
Compliance with data protection regulations is the responsibility of the operator of the software (responsible
authority).

5 Digital Machine
The digital machine is a sample project with Control plus using Beckhoff TwinCAT 3.1. The sample project
represents an automatic assembly station and serves only as an illustrative example for the Control plus
automation software from Nexeed Automation.
The sample project is not intended for productive operation. The Freeware License Terms and General Terms and
Conditions of Bosch Connected Industry apply.
Please refer to the help function in Control plus Studio. In addition, the later sections of this document provide
solutions to problems associated with the sample project.
Any further questions can be asked in the Nexeed Automation Community forum:
https://community.developer.bosch.com/t5/Nexeed-Automation/ct-p/bosch_developers-nexeed-automation
6 System requirements/settings
6.1 System Requirements
▪ Windows 10, 64-bit
▪ .NET Framework 4.5
▪ If the PLC project is to be started, a functional TwinCAT Runtime is required.
The system requirements must be checked by Beckhoff.
▪ A powerful, up-to-date PC is required for smooth and error-free operation. It is recommended to use a
controller supported by Control plus (e.g. Rexroth VPB40.4 or Beckhoff C6930 with Control plus Master
Image). Operation on other systems is not in the scope of the services of Control plus and is carried out at
the user's own risk and without support.

▪ In conjunction with some laptop docking stations, performance issues have been noticed during
tests, especially when using more than two screens.
▪ Further requirements can be found in the software packages ( Necessary Software Packages see
page 7) to be installed.

6.2 Necessary Software Packages

▪ Control plus Studio V5

https://www.bosch-connected-industry.com/de/en/downloads/automation/control-plus/
engineeringsystem.html
▪ TwinCAT XAE 3.1.4024

https://www.beckhoff.com/en-en/support/download-finder/software-and-tools/

▪ Click the checkbox to install TcXaeShell during installation. Installing Git is optional.
▪ In the event of installation errors, contact Beckhoff support.

▪ TF6310 (TCP/IP)

https://www.beckhoff.com/en-en/support/download-finder/software-and-tools/
▪ TF6100 (OPC UA server)

https://www.beckhoff.com/en-en/support/download-finder/software-and-tools/

▪ Only the OPC UA server is required, not the client or configurator.

▪ Activate Enable none/none endpoint during installation.

6.3 Configuring Settings for Operation without D:\ Drive

By default, the sample project requires read/write permissions for the D:\OpconData folder.
If there is no D drive, make the following changes:

1. Open file Stat000\Engineering\Stat000.cpsp with Control plus Studio.

 2. Use CTRL + F to open the search dialog and search for D:\ .

3. Manually replace all locations found with C:\ .

4. Save and close the settings.

The batch files do not work in the Windows user folder (e.g. C:\Users).

6.4 Configuring OPC UA Server Settings

After installing TF6100, set up the OPC UA server so that the following client connections are possible:
▪ Connection without authentication
▪ Connection without signing and encryption

▪ The procedure is carried out at the user's own risk.

▪ The two XML files deactivate all Beckhoff OPC UA server security settings. Any OPC UA client can
connect to the OPC UA server and execute all operations available via OPC UA (e.g. reading and
writing PLC variables). Operation without OPC UA security is carried out at the user's own risk.

1. Copy the two XML files from the __Readme\TF6100-OPC-UA_Win32_Server folder to the C:\TwinCAT\Functions
\TF6100-OPC-UA\Win32\Server folder.

The OPC UA server is set up. If the OPC UA server has not been set up correctly, a red error message will
appear later in the command line:

6.5 Settings for Operating the Cycle Time Assist and Part Counter
Services
If the apps/services for Cycle Time Assist and Part Counter are to be run, SQL Server Express with write
permissions is required for the system user NT AUTHORITY\SYSTEM.
If no SQL server is installed or if the services cause the following error to appear in Windows Event Viewer during
start-up, perform the installation as described in the following steps.

Enabling write permissions for the system user NT AUTHORITY\SYSTEM can be a security risk and is
carried out at the user's own risk.
 1. Download SQL Server Express 2019 Basic from Microsoft as an offline installation (SQLEXPR_x64_ENU.exe).

2. Place the installation file SQLEXPR_x64_ENU.exe in the __Readme\SQLEXPRESS folder.

3. Run the batch file __Readme\SQLEXPR_x64_ENU_Install.bat with administrator rights.

The services can now be used.

7 Start the Digital Machine

The project with 3D simulation can be started partially automatically with batch files. Alternatively, all steps can be
performed manually:
Starting the Digital Machine with Batch Files (see page 9)
Manually Starting the Digital Machine (see page 11)
After the first start, the robots have to be set up:
Setting Up the Robots and Removing HMI Error Messages (see page 13)
If the TwinCAT Runtime does not start, some system settings have to be checked:
Troubleshooting — TwinCAT Runtime (see page 16)

7.1 Starting the Digital Machine with Batch Files

1. Run 01_OpenProject.bat.

2. Start the PLC export in Control plus Studio to install the required libraries.

If an error message appears, restart the export.

If there is no D drive available and the paths have been changed, also start a full export.

3. Run 02_RunDataSetAccess_D_Harddisk.bat or 02_RunDataSetAccess_C_Harddisk.bat.

Changes must be made in Control plus Studio to allow for operation on the C drive. To do this, configure the
following settings. Configuring Settings for Operation without D Drive ( Configuring Settings for Operation
without D:\ Drive see page 7)

4. In TwinCAT, under Real-Time > Settings, click Read from Target once.
 The TwinCAT Runtime is launched on the target system.

Programming errors or unexpected errors can result in data being lost on the target system, e.g. when
a blue screen occurs.

If Activate Configuration does not work, information can be found here Troubleshooting — TwinCAT
Runtime (see page 16).

5. Activate the configuration in TwinCAT.

6. Log in to the target system.

7. Start the PLC.

8. Optional (not required for operating the digital machine): Run 03_RunAppServices.bat for Cycle Time Assist
(CTA), Part Counter, Shift Manager and Event Recorder/Event History.

The services then start automatically every time Windows is booted up and can be removed from the
system again with the batch file 99_UninstallAppServices.bat.

9. Run 04_Run3DSimu.bat.
 When starting the 3D simulation for the first time, an Internet connection is required for activating the
license.

10. Start the mPad HMI locally in Control plus Studio.

The digital machine is started. To ensure smooth operation, initially set up both robots (location =120 and
=130) and remove the HMI error messages. ( Setting Up the Robots and Removing HMI Error Messages see
page 13)

7.2 Manually Starting the Digital Machine

1. Open Stat000\Engineering\Stat000.cpsp and Stat000\Plc\Stat000.sln.

2. Start the PLC export in Control plus Studio to install the required libraries.

If an error message appears, restart the export.

If there is no D drive available and the paths have been changed, also start a full export.

3. Copy the content from Stat000\Targets\VPB40.4\OPCON_DATA_PATH to D:\OpconData\.

The target folder must be empty before copying.

Alternatively, copy to C:\OpconData. To do this, configure the following settings. Configuring Settings for
Operation without D Drive ( Configuring Settings for Operation without D:\ Drive see page 7)

4. Copy Stat000\DataSetAccess and Std\DataSetAccess to a shared folder.

To keep the project neat, it is logical to create a separate new folder. Do not copy files to the Std folder.

5. Start Opcon.DataSetAccess.Diagnostic.exe in the new folder, then click on the Play button.

6. In TwinCAT, under Real-Time > Settings, click Read from Target once.
 The TwinCAT Runtime is launched on the target system.

Programming errors or unexpected errors can result in data being lost on the target system, e.g. when
a blue screen occurs.

If Activate Configuration does not work, information can be found here Troubleshooting — TwinCAT
Runtime (see page 16).

7. Activate the configuration in TwinCAT.

8. Log in to the target system.

9. Start the PLC.

10. Optional (not required for operating the digital machine): Run _Batch\03_RunAppServices.bat for Cycle Time
Assist (CTA), Part Counter, Shift Manager and Event Recorder/Event History.

The services then start automatically every time Windows is booted up and can be removed from the
system again with the batch file 99_UninstallAppServices.bat.

11. Start 3D_Simu\Digital Machine.exe.

 When starting the 3D simulation for the first time, an Internet connection is required for activating the
license.

12. Start the mPad HMI locally in Control plus Studio.

The digital machine is started. To ensure smooth operation, initially set up both robots (location =120 and
=130) and remove the HMI error messages. ( Setting Up the Robots and Removing HMI Error Messages see
page 13)

7.3 Setting Up the Robots and Removing HMI Error Messages

For the robots at positions =120 and =130, tools must initially be transferred to the persistent data by editing
them in the HMI and explicitly saving them.

1. Switch to manual mode (Manual) and edit the tools marked in red for the robots =120+M-M741 and =130+M-
M741 using the Edit button.

2. To save the changes, click on Save & quit.

 If the robot tools have not been transferred to the persistent data, the following error message is thrown
during homing:

3. In the Status view, click Control on to turn on the controller/power.

4. Move to the starting position via Homing and select and start the Automatic operating mode by clicking the
Play button on the right-hand side.
5. In the Functions view under Operation, check whether an operator dialog is present.

If the robot error message Robot does not move to the home position is present, the robot is probably not in a
defined area and must therefore be moved manually.

6. Select manual mode, acknowledge the error and edit the help point list:

7. Select Home Position and move to it by clicking and holding the button until the home position is reached.
 If an inconsistent data status occurs as a result of restarting the PLC or simulation and if a gripper error
message is thrown, the persistent data can be deleted individually or all at once in manual mode in the
following HMI view. It is recommended that you restart the 3D simulation after deleting the data.
▪ The buttons can only be accessed by a service user (password required).
▪ The group boxes displaying data are arranged roughly as the positions appear in the top view of the
machine.

7.4 Troubleshooting — TwinCAT Runtime

Known error messages:
▪ Setting TwinCAT in Run Mode inside HyperV (virtual machine) is not possible. Do not use HyperV. 0x1024
▪ AdsError: 4132 (0x1024, RTIME: incompatible software detected)
▪ TCRTIME (200): start of real-time avoided by "HyperV"
▪ AdsError: 4115 (0x1013, RTIME: system clock setup fails)
If any of these errors occur when the TwinCAT Runtime is started up, the following settings can help.
 The settings are configured at the user's own risk. Changing these settings may cause other software
on the PC to stop working or security vulnerabilities may occur.

1. Find Hyper-V in the start menu and disable it in Windows Features:

2. Run the following batch file as an administrator (context menu > Run as administrator):

C:\TwinCAT\3.1\System\win8settick.bat

After execution of the batch file restart Windows.

3. Use isolated cores. To do this, run Read from target, set the number of isolated cores in the second field, run
Set on target, then restart Windows and activate the configuration.

The last cores should be used and an even number of cores should remain for Windows.

4. TwinCAT 2 must not have been installed after TwinCAT 3 or must have been deactivated when installing
TwinCAT 2 using SwitchRuntime.exe. If TwinCAT 2 has been installed retrospectively, TwinCAT 3 can be
installed over it again.
5. Even if the Hyper-V setting from step 1 has been disabled: If the system is running an operating system
resource or program that uses Hyper-V, Hyper-V is active in the background. For example, if virtualization-
based security is enabled, TwinCAT will not run on the system.

The corresponding Windows settings must be applied or must be changed via command line with BCDEdit.

On Bosch computers Hyper-V and virtualization-based security can be deactivated via My IT Services (Add/
Remove Software).

6. Enable the VT-x-CPU (virtualization) feature in the BIOS.

7. If none of these steps have helped so far: Disable Hyper-Threading in the BIOS (= default setting in Nexeed
Master Image).

In Windows, only the real number of CPU cores is available (e.g. 4 instead of 8).
8 Service – Helpdesk
If technical assistance is needed or if you require more information about our products and solutions, please
contact the Help Desk via the following channels.

+49 (711) 811-8811

Monday to Friday 08:00–16:00 (GMT+1)

[email protected]

www.bosch-connected-industry.com
Contact form

9 Index
C
Configuring OPC UA Server Settings 8
Configuring Settings for Operation without D:\ Drive 7

D
Digital Machine 6

F
Foreword 3

G
General Information 4

I
IT security and data protection 6

M
Manually Starting the Digital Machine 11

N
Necessary Software Packages 7

S
Service – Helpdesk 19
Setting Up the Robots and Removing HMI Error Messages 13
Settings for Operating the Cycle Time Assist and Part Counter Services 8
Start the Digital Machine 9
Starting the Digital Machine with Batch Files 9
System Requirements 7
System requirements/settings 7

T
Troubleshooting — TwinCAT Runtime 16