Flexible. Expandable. Modular. Affordable

Transcription

1 The CIM System is a manufacturing model for the unmanned factory of the future. It is used for teaching and training of manufacturing engineering students in areas related to automation, material handling, system integration, CNC machining and robotics. The system is designed for flexible manufacturing and allows a wide range of machine tools, automation devices and software to be integrated. It has an open system concept whereby manufacturing software such as CAD/CAM, databases, MRP, ERP are easily integrated Automatic Storage and Retrieval System (ASRS) CNC Lathe Machine CNC Milling Machine Robots Assembly/Quality Control Station Closed Loop Conveyor System Barcode Scanning System Central Management Control Station (CMCS)

2 Typically, a work piece, which is located at the ASRS, will be placed on the conveyor system by a gantry robot. The conveyor will transport the work piece to the CNC milling machine where another robot will pick up the work piece from the conveyor belt and place it in the machine. After the milling process, the robot will return it to the conveyor belt where another robot will pick up the work piece and place it in the CNC lathe machine. After the work piece has been machined, it will be transported by the conveyor belt to the assembly station for assembly and QC check. If the work piece is satisfactory, it will then be bar coded at the next station and transported to the ASRS for inventory purpose. The whole process is controlled by a Central Management Control Station (CMCS), which sends the exact instructions to the various stations for the work to be performed. The conveyor belt serves as a transport highway where the work piece will be loaded and sent on to its destination. Flexible It is possible to integrate the CIM with a wide range of machines and automation devices and to interface with third party software. Expandable Hardware or software can be added over a period of time, expandaing from a simple Flexible Manufacturing Cell (FMC) with one machine and one robot, to a complete CIM system. Modular Each module in the CIM is capable of performing its own task, independent of the rest of the system, allowing the different subject areas to be studied separately. Affordable The CIM is controlled by PC s using windows-based software together with machines and automation devices configured to suit the budget available.

3 1. Automatic Storage & Retrieval System ( ASRS ) 40 Bay Automatic Storage and Retrieval System (ASRS) The ASRS is constructed using extruded aluminum and incorporates a precision gantry robot with X, Y, Z and θ axis linear slides. This 40 bay ASRS consist of two parallel pallet storage racks each comprising 20 pallet storage locations per rack (4 vertical and 5 horizontal). Component storage systems can be designed to suit customer application ranging from simple magazine loading to a completely automated palettized storage and retrieval systems. Raw material and finished products can be automatically retrieved and stored managed by a host computer. All parts and assemblies are transported by the ASRS on standard carrier pallets allowing material to be supplied to the manufacturing sytsem at the same time for batch orders involving different products. The gantry robot is designed to remove a pallet from the storage bay and place it onto the conveyor ready for transportation to the first manufacturing operation. On the completion of the manufacturing process, and following a command from the cell controller, the robot will collect the pallet and replace it in the appropriate rack on the ASRS. 2. CNC Milling Machine This machine can be operated as a manually controlled vertical milling machine and also as a numerically controlled machine Component and pallet transfer from the ASRS to the machines can be accomplished using conveyor. The ASRS system can be designed accodring to customer requirements on the number of storage bays.

4 features R user friendly software with 3D graphical simulation and automatic error checking. R ISO format machine programming using G and M codes included as standard. R Active and accurate tool path graphics continuosly displayed line by line during program write, test run and manufacture. R Links with major CAD/CAM packages. Spindle speeds: 350 to 3500 rpm Rapid traverse rate at 100%: 600mm/min (24 /min) Pragrammable feed rates: 10 to 600mm/min (0.4 to 20 /min) Axis travel X(longitudinal) 190mm(7.4 ) Y(cross) 125mm(4.9 ) Z (vertical) 140mm(5.5 ) System resolution: 0.005mm Table dimensions: 370 x 130mm (14.5 x 5.1 ) Spindle to table: 202mm (7.9 ) Centre line of spindle to column: 130mm(5.1 ) Table of column: 5 to 130mm (0.2 x5.1 ) Tee slots: 2x10mmx100mm centres 1. Automatic 5 position tool changer 2. 80mm 3 jaw self centring chuck mm 4 jaw independent chuck mm 3 jaw self centring chuck 5. Recommended set of 5 tool holders 6. Recommended set of tooling 7. Woodworking attachments 8. Cabinet base with lockable door and computer shelf 9. Emergengy foot switch 11. Airmist coolant system 12. Machine vice 100 x 75mm capacity 3. CNC Lathe Machine This machine can be operated as a normal lathe and as a CNC machine through its internal CNC system. Feeding in of program is via control panel of the CNC unit together with storage and retrieval of programmes and through interfacing with the CAD/CAM system. All programs uses ISO code. Accessories features R CAM user friendly software with 3D

5 graphical simulation and automatic error checking. R ISO format machine programming using G and M codes included as standard. R Active and accurate tool path graphics continuosly displayed line by line during program write, test run and manufacture. R Links with major CAD/CAM packages. Spindle speeds: 200 to 3200 rpm Rapid traverse rate at 100%: 1200mm/min (48 /min) Pragrammable feed rates: 10 to 999mm/min (0.4 to 20 /min) Axis travel X(cross) Y(longitudinal) System resolution: 0.005mm Swing over bed: 125mm(4.9 ) 125mm(4.9 ) 160mm(6.2 ) Swing over X axis slide: 70mm(2.7 ) Swing over gang tooling plate: 50mm(1.9 ) Spindle bored to pass: 20mm (0.75 ) Tailstock: Quill travel 75mm (2.9 ) Spindle taper 2MT 1. Automatic 8 station tool post 2. Airmist coolant 3. Low volt light 4. Tailstock 5. Cabinet base with lockable door and computer shelf 6. Emergency footswitch 7. Chucks - 80mm 3 jaw - 100mm 4 jaw independent - Power chuck 9. Standard set of tools and inserts 10. Standard set of tool holders with inserts 11. Z axis limit switch 12. Rotating tailstock centre 13. Woodworking attachments 4. Robots Eshed Robotec s SCORBOT-ER IX robot is the latest in a growing family of DC servo robots. The robot arm is vertically articulated having harmonic drives on all five points. The feedback system utilises C-pulse optical encoders for high homing repeatedly of the robot. Accessories SCORBOT-ER IX : High Performance Robot

6 Mechanical Arm Number of Axes : 5 plus gripper Operating Radius : 691mm at flange (27.2 ) Axis Movement : Axis Effect. Max. Range Speed Speed Axis 1: base rotation /sec 112 /sec Axis 2: Lower Arm /sec 99 /sec Axis 3: Upper Arm /sec 112 /sec Axis 4: Pitch /sec 133 /sec Axis 5: Roll /sec 240 /sec Load Capacity : 2kg(4.4lbs) Repeatability : ±0.09mm Gripper : Electrical (DC) or pneumatic ACL type B controller CPU: Motorola 68020, Motorola FPU- MC EPROM: 512KB, stores thousands of positions and program lines. User RAM: 512KB battery backed. Communication: 10 RS232 Channels, bidirectional parallel port. Programming Language: 1. ACL (Advanced Control Language) multitasking and real-time robotic language. 2. SORBASE-menu driven user friendly conversational command environment. Teach Pendant: 25 multi-function keys, 4x15 digit LCD display. Vision Inspection System Inspection is an important part of any manufacturing process being used for: R detect parts which are incorrectly manufactured R detect parts which have incorrect orientation for further processing R identify measurements of material/ components/assemblies in process R make measurements of material/ components/assemblies in process 6. Closed Loop Conveyor System CIM system incorporate a conveyor which carries material, components or assemblies on carrier plates call pallets. The conveyor has a continuously moving belt to transport the pallets to positioning stations where the pallet is stopped and locked into position, ready for work to be done with the material on the pallet. As a option to Eshed robots we can offer FANUC industrial robots from Japan. 5. Assembly/Quality Control Station Simple or complex assembly applications can be performed; uses Eshed s vertically articulated robots; quality control stations with vision system, height gauge, CMM or LSM; interfaced with SPC (statistical software).

7 The closed loop pallet conveyor is fully compatible with the range of Robots, Machine Tools, ASRS and other hardware elements. It is integrated with the rest of the system software through the use of a special device program which supervises the movement of all pallets. Specification of the conveyor system: Length:Approx. 200mmx1800mm(circulating) Height: Approx. 900+/-30mm Speed: 10-15m/mm(variable control by inverter) Motor: 250watts, SEW AC 415V-3Ph Conveyor drive unit: Catenary Conveyor width: for 240x240mm pallet Conveyor supplied is free flow chain conveyor and can be supplied with pallet stoppers and locator units. The stopper an dlocator units are mounted on aluminium profiles with T - slots with flexibility of relocating the position. Conveyor is supplied with the following items: RModular design enabling the system to be configured to suit the customer's requirements. R The standard closed loop conveyor system is supplied with ten carrier pallets with the size of 240mm x 240mm R Control box and PLC based control system with selector switch for Auto and Manual function R The drive system is protected against overload and short-circuiting R Emergency Stop 7. Barcode Scanning System The Bar Code Reader used in the CIM system is a moving beam Bar Code scanner with a build in decoder which is particularly suited to applications requiring high reading performance, small sized and low cost. The decoder provides a data comparison feature which enables the good read/bad read decision to be based upon a predetermined code. The scan and decode speed is 500 per-second which enables reading of moving bar code. Applications: R Conveyor system for work progress monitoring R Automatic Storage Systems for Inventory Tracking R Components Identification 8. Central Management Control System (CMCS) The whole process is controlled by a Central Management Control Station (CMCS), which sends the exact instructions to the various stations for the work to be performed. CIM Control Software The Three Level Hierarchical Structure As with any manufacturing method, it is the design of the control software architecture which determines the accuracy of the process; and to give optimum efficiency and flexibility, the CIM control software, FACTORY FLOOR, has a three level hierarchical structure to control the various elements within the system. A) System Control Level - HOST The responsibility of the host computer, which is the main user-interface to the manufacturing system, is to supervise and co-ordinate the entire manufacturing process it does this by delegating individual tasks to the next level in the hierarchy. B) Supervisory Control Level - CELL The intermediate stage of the CIM is the responsibility of the cell controllers. These can utilise different levels of scheduling sophistication from basic machine operation to complex scheduling tasks.

8 C) Manufacturing Level This covers the actual machines required to produce the component i.e. milling machines, lathes, robots, storage systems. Measuring systems etc. Each has its own in-built computer and can hold data for its specific tasks. Factory Floor : OptoControl, Flow Chart Programming

9 The courses are divided into 10 groups, namely : 1) Master CAD/CAM - Introduction to AutoCAD and CAD/CAM software. 2) CNC programming for Turning and Milling operation 3) Robot Programming and Maintenance 4) Introduction to PLC Programming 5) Inspection System and Tagging System 6) CIM 1 - CNC Lathe/Mill, Linear Slider Base 7) CIM 2 - Palletised Conveyor. 8) CIM 3 - Automatic Storage & Retrieval System (ASRS) 9) CIM 4 - Central Management Control System (CMCS) 10) CIM 5 - Enterprise Resource Planning Courses Description 1) Master CAD/CAM - Introduction to AutoCAD and CAD/CAM software MasterCAM is a combination of AutoCAD and CAD/CAM software which is powerful, versatile CAD/CAM software designed to produce high-quality parts faster and with great accuracy. Choose from 2-through 5 axis milling, turning, wire EDM, Lasers, mold base development, 3D design, drafting and surface modelling solutions. MasterCAM is continually updated and expanded, giving you the features needed for maximum productivity. This course is design to equip the participant with basic knowledge of AutoCAD and MasterCAM. The participant is exposed to Milling and Turning operation, 2D-3D drawings, Advanced C axis (Mill/Turn) Programming, Main Features utilities using up- to date CAM software. a) Overview AutoCAD and MasterCAM software b) Entity creation c) Co-ordinate system and viewing d) Transformation functions and editing e) CAD/CAM features and solutions for 2 through to 5 axis milling, turning, wire EDM, lasers, mold base development, ID design,drafting and surface modelling. f) Process planning for turning and milling g) Tool path and code generation h) Machining simulation 2) CNC Hardware and Programming for Turning and Milling operation CNC Machine is the building block of the machine that have been chosen to ensure productivity, reliability, flexibility and thus optimum utilisation of the machine. The machine allow with appropriate optional accessories and software, easy integration with a Turning/Milling into a Computer Integrated Manufacturing (CIM). To equip the participant with a basic knowledge of computer numerical controller

10 with respect to Turning and Milling operations. Upon completion of this course, The participant should be able to do CNC Programming, set-up and machining. a) Fundamentals of CNC usage : Specification, part description, Main features b) Basic machining practice and CNC manual programming c) Set-up and operation for CNC Milling/ Turning d) Co-ordinate system e) Tolerance and Dimension f) CNC Programming - 2D g) 3-Dimension and parametric Programming h) Blueprint reading and Shop math i) Parametric programming for CNC j) CNC Tooling for Turning/Milling operation k) Macro and sub-routines functions 3) Robot Programming and Maintenance The robot systems provides, flexible and exceptional cost-effective solution for pick and place, loading unloading task. Features benefit : a. High speed and high precision b. Expandable compact controller c. A versatile range of model backed by a wealth of option d. Improved reliability and easier maintenance e. Attractive designs and safe operation f. Easy to use This course is designed to equip the participant with skills and knowledge of robot programming and maintenance. Upon completion of this course, the participant will be able to troubleshoot the robot system and enhance the utilisation of robot in any environment. a) Robot Overview b) Robot hardware and configuration c) Robot system components d) Total connection of robot system e) Teach pendent operation f) Robot co-ordinate system g) Robot production running h) Component replacement i) Robot operation and motion software set -up j) Identify safety precautions k) Robot program 4) Introduction to PLC Programming PLC is a flexible controller that can control an input/output signal from all equipment. This PLC becomes a master controller for total communication between field devices and the Central Management and Control System. By PLC sequence program, the signals are then transmitted to all robot and other devices such as actuators etc. This course is designed to give a knowledge to participant about PLC programming and configuration between PLC and other devices. a) PLC Trainer Cell configuration b) I/O Modules connection c) PLC Familiarization d) PLC Trainer flowchart design e) PLC Interfacing

11 5) Vision InspectionSystem and Bar code Tagging System Vision system is the combination of image sensor and computer technology, enabling automated decision making based on visual information. A vision system can deliver inspection data that forms the basis for automatic product quality control. The inspection output data is the input signal for a handling system that sorts out faulty items. This vision system is the key to many manufacturing production, process and automated need. The main components of these system are: a) Camera Closed Circuit TV (CCTV) b) Image Monitor c) Computer d) Power Supply e) Lighting Inspection is an important process being used for : R Detect parts which are incorrectly manufactured R Detect parts which have incorrect orientation for further processing R Identify materials/components/ assemblies in process R Make measurements of materials/ components/assemblies in process The Bar code Reader used in the CIM system is a Moving Beam Laser Bar Code scanner with a build in decoder which is particularly suited to applications requiring high reading performance, small size and low cost. Applications : R Conveyor system for work progress monitoring R Automatic Storage Systems for Inventory Tracking R Component Identification This course is designed to give a knowledge to participant about overall CIM inspection and part recognition system. Includes 2D & 3D pattern recognition and overall tagging system concepts. a) Introduction to Vision system b) Evaluating a Vision system Application c) How to select Camera and Lenses d) Vision system algorithms e) Software setting f) Introduction to Tagging and inspection system concept. g) Tagging and Inspection system function, operation and hardware set-up h) Software Development - sensing, preprocessing, segmentation, description, recognition, interpretation i) High level of system integration with all equipment - system interface. 6) CIM 1 - CNC Lathe/Mill, Linear slide base CNC Lathe/Mill and Linear slide base must be integrate together to get a continuous and fluent process during to do a task. This must be integrate within hardware and software. To equip the participant with a basic knowledge of CNC Lathe/Mill, linear slide base main hardware features and integration. Upon completion of this course, the participant should be able to understand and trouble shooting the CNC Lathe/Mill and linear slide base. a) Introduction of the hardware part for CNC Lathe/Mill, and configuration of linear slide base b) CNC Lathe/Mill hands-on troubleshooting and set-up.

12 c) CNC Lathe/Mill Tooling (jig and fixture). d) Component replacement. e) Integration between CNC Lathe/Mill and Linear Slide Base. f) Input and Output data. 7) CIM 2 - Palletised Conveyor The CIM system can incorporate a conveyor which carries material components or assemblies on carries call pallet. The conveyor has a continuously moving belt to transport the pallets to positioning stations where the pallet dropped and locked into position, ready for work to be done with material on the pallet. This conveyor is fully compatible with robots, machine tools, ASRS and other hardware element. It is integrated with the rest of the system software through the use of a special device driver program which supervises all movement of all pallets. This course is designed to introduce the participant about function of this palletised conveyor, integration with other component. Upon completion of this course, the participant will understand more the purpose and integration with the CIM. a) Overview of Palletised Conveyor, part description, specification b) Input/output link and set-up c) Cell controller and device driver program d) Palletised hardware design and features - Size, load calculation, accuracy, repeatability, speed and cost. 8) CIM 3 - Automatic Storage & Retrieval System (ASRS) Component storage can be designed to suit customer application ranging from simple magazine loading to a completely automated palletized storage and retrieval systems. Raw material and finished products can be automatically retrieved and store manage by a host computer. All parts and assemblies are transported by the ASRS on standard carrier pallets allowing material to be to the manufacturing system at the same time for batch orders involving different products. This course is designed to equip the participant with skills and knowledge of ASRS. Upon completion of this course, the participant will be able to understand the process flow, software control and hardware integrated with other equipment for this ASRS and enhance the utilisation to set-up in any environment. a) Overview - ASRS function, operation, configuration b) Software development - a process configuration c) ASRS main component - hardware, component set-up d) Planning and scheduling system 9) CIM 4 - Central Management Control System (CMCS) Central Management Control System provides monitoring and control to overall peripheral and a communication for CMCS is linked by a configuration of Local Area Network. Other station like PC, PLC and others can be linked also by this LAN and provides communication facilities between them. From the PC station, user can run a certain program to edit and monitoring the process of work cell by a special software such as PARAGON, MAX ERP. The design of the control software architecture determines the accuracy of the process.

13 This course is designed to equip the participant with a knowledge of Central Management Control System, Configuration, Hardware and software development. a) CMCS Overview and Design Layout b) CMCS Configuration and interfacing with other peripheral c) CMCS Hardware link and software control d) CMCS integration with peripheral e) LAN and configuration f) Man Machine Interface g) Simulation CIM 5 - Enterprise Resource Planning Enterprise Resource Planning (ERP) is a software company built entirely by seasoned manufacturing to produce real time result on the shop floor and at the bottom line. ERP provides user with the flexibility by which to achieve user goals at a cost that deliver s true value for money and wastes nothing. From ERP also user can choose from over 30 fully integrated core and expansion modules, covering the full range of manufacturing and accounting requirements. This course is designed to equip the participant with skills and knowledge of Enterprise Resource Planning. Upon completion of this course, the participant will be able to understand the main features of the software and use it in optimum rate. Syllabus: a) Executive: Management, Performance, MaxGraph, Max Insight EIS. b) MIS: Utilities, Report Writer, MaxWAN, MaxAccess, MaxUpdate, Transaction Load, System Managers Tool-kit, Global Maintenance. c) Inventory Control : Multiple Record processing, Visual Transaction History, Cycle count, Security, User definable field, Reports. d) Engineering : Bill Of Material, Configurator, Manufacturer Part Control. e) Manufacturing : Shopfloor control, Repetitive manufacturing, Labor tracking, Lot Tracking. f) Sales Customer Service : Sales order entry, Quoting, configurator, EDI, Multi-currency, Warranty Tracking. g) Purchasing : Purchasing control, Subcontract processing, Manufacturers Part control, Multi-currency. h) Planning : Master Scheduling, MRP, Simulation, Corporate Consolidation, Visual Scheduler, Subcontract Processing. i) Accounting : Accounts Receivable, Accounts Payable, General Ledger, Costing, Multiple costs, Multi-currency.