FMS 100. Manual. Hydraulic station

Transcription

1 FMS 100 Manual Hydraulic station

2 Order-NR.: Type: Designation Manual FMS FMS100_Hydraulic_A001 Printed: Autor: Graphics: Layout: Schober Schober Schober Festo Didactic GmbH & Co.KG., D Denkendorf, 2003 Internet: This manual, all text and illustrations contained included, is protected by copyright. Any utilisation outside the limits of the copyright law and other than training purposes are not permissible without our definite approval. This applies in particular to reproductions, operations, translations, micro filming and the storing and processing into electronic systems. Parts of this manual may be copied by the authorised user, exclusively for teaching purposes. Distribution of this documentation, as well as reproduction, use and spread of its contents is prohibited, insofar not permitted explicitly. Offences are liable to compensation. All rights reserved, especially the right to execute registrations concerning patents, designs for use and patterns. 2 Festo Didactic GmbH & Co.KG. FMS 100

3 1 Intended use The User Manual must be to hand at all times. Keep it close to the machine. This installation was developed and manufactured only for use in basic and further training in the fields of automation and communications. The training company and/or the training staff must ensure that the trainees observe the safety precautions described in the accompanying manuals. Furthermore this manual describes setup and possible uses of the singular stations. It contains all information and data required for commissioning, maintenance and operation. Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any third parties occurring when the installation is used for any purpose apart from training, except Festo Didactic has caused such injury or harm intentionally or by grossly negligence. The manual is divided into four parts: Part A In addition to technical data, Part A contains an overview of the possible uses of the stations. Part B Part B contains some exercises and the solutions for this exercises (Not available for each station). Part C Part C contains the pneumatic and electrical diagrams for the station and the listing of the control programs (Not available for each station). Part D Part D contains data sheets and technical information about the electrical and electronic modules used. Festo Didactic GmbH & Co.KG. FMS100 3

4 List of applicable standards and regulations The list below provides an overview of the most important standards and regulations relating to mechanical, electrical and safety-engineering design and production. DIN EN 292 -Machine safety DIN EN Electrical equipment of industrial machines DIN VDE See DIN EN DIN Circuit documentation VDI Technical safety requirements concerning the building, equipping and operation of industrial robots VDI Technical safety requirements concerning automated production systems VDI Terms and explanations in conveying and handling VDI Assembly and robotics - terms VDI Assembly and robotics - characteristic quantities DIN PROFIBUS Part 1-3 As far as possible, the System is maintenance-free. All bearings are lubricated for life. The installation was designed in such a way as to keep the number of wearing parts to a minimum. This does not include machines that are part of optional expansions (such as industrial robots). At this point we would like to point out that this manual and the concept of the operating instructions for a Flexible Training System of this type are regularly updated. To ensure that the instructions are ever more user-friendly, you would help us a great deal by passing on your suggestions for improvement. Please let us know of your suggestions, corrections or ideas, either in writing or via telephone: +49( ) 4 Festo Didactic GmbH & Co.KG. FMS 100

5 2 Contents 1 Intended use 3 2 Contents 5 3 Introduction General Hydraulic station Didactic structure Scope of tasks of the stations Mechanics Pneumatics Electrics Informatics Bus technology 12 4 General safety instructions Use according to regulations Handling the system Dangers in handling the machine Safety precautions in standard operation Dangers due to electric current Dangers due to pneumatic energy Maintenance Servicing Malfunction removal Organisational measures Personnel 16 Festo Didactic GmbH & Co.KG. FMS 100 5

6 Contents Notes on personnel Training operations Outside training operations Safety symbols 17 5 Commissioning Transport Set up General information Set-up of the hydraulic station Commissioning Pneumatic commissioning Electric commissioning Connecting communication cables Start up the system Start up conditions general information Adjust AS/RS station Soldering station Robot assembly station Hydraulic station Adjust transport system CNC-coupling station 28 6 Festo Didactic GmbH & Co.KG. FMS 100

7 Contents Vision station Start up cell control and COSIMIR CONTROL Start-up of processes Shut down the system 29 6 Operation General operation notes Behaviour rules Operation rules Process description Hydraulic station General information Order codes Hydraulic station Servo-pneumatic feeder PLC-COSIMIR CONTROL Order codes Hydraulic station press PLC-COSIMIR CONTROL Control strip hydraulic station Reset mode Automatic mode Activating automatic mode and starting the process with network _ Automatic start up Automatic stop Manual mode Manual start-up Manual stop 40 Festo Didactic GmbH & Co.KG. FMS100 7

8 Contents 6.9 Teach mode 41 7 Technology drawings Modules in use Palette reception Transfer unit Servo positioning axle Hydraulic press Assembly device Workpiece positions Technical datas 51 8 Pneumatic The valve terminal Pneumatic supply 54 9 Electrical system Power supply Controller Controller design Siemens S Controller design SPC Wiring I/O-Components 59 8 Festo Didactic GmbH & Co.KG. FMS 100

9 3 Introduction 3.1 General This user-defined installation contains parts of the FMS 100 system, mixed together with other components. The installation, thus created, is explained in the following operational manual and the respective station manuals. In the development of the system, various production technologies have been combined into one installation. The aim of the installation is the increase of competence, from a simple setting of examples up to a complete production process, including all features. Additionally, to technical and social competence, the comprehension of the process and the interaction of the respective components appear in clear presentation. This manual describes working with the FMS system. Everything is explained and described for the operation of necessary events. With the help of graphics or pictures a simple communication should be obtain. Complete operating instructions which explain the processes of the system are available for working with the system. Station manuals are also available for the individual stations. Additionally to technical and social competence, the comprehension of the process and the interaction of the respective components appear in clear presentation. Festo Didactic succeeded in using the most updated industrial hard- and software for this model production. Festo Didactic GmbH & Co.KG. FMS 100 9

10 Introduction 3.2 Hydraulic station The hydraulic station is responsible for pressing connection pins into an electronic handheld device. Once an order exists for pressing pins into a handheld device, a palette containing assembled handheld devices is requested and placed onto a palette reception. At this point, a pre-assembled handheld device is taken off the palette to be placed into the assembly device. The assembly device moves into the press. The safety door is being closed. The actual pressing process commences. The pressing process is controlled by the stroke length. Once all of the pins have been pressed, the stamp of the press moves upwards. Afterwards the safety door is opened up. The assembly device moves out of the press and the handheld device can be returned to its retrieval position on the palette. Afterwards the second handheld device is being pressed, which concludes the pressing process. The handheld devices are stored in the AS/RS station for further use. The station possesses its own control cabinet, which is fitted into the basic frame of the station. A Siemens S7 supplies the control and a SPC is responsible for the servo pneumatics. Communication to the other stations ensues by Profibus FMS. The hydraulic station can be operated individually, in stand alone mode, for training purposes in the servo pneumatics area and programming. 10 Festo Didactic GmbH & Co.KG. FMS 100

11 Introduction 3.3 Didactic structure The installation is structured, to enable methodical learning, i.e. from single use of modules to the complex and complete installation. Perhaps even in combination with further systems. For example, it is possible to pick out a single module to start with the first steps, e.g. the robot. First the mechanical assembly is considered. The robot s radius of action requires integration into the location of the robot. The following step could be the connection of all cables required for operation and the set-up of the robot. Moving the robot and teaching the required positions are the first real operations with the robot, which introduces the user how to deal with the teach-box. The robot s programming can be started, as soon as the robot can be moved by the teach-box. Small programs, which can be created by using the Cosimir/Cosirob software, are expandable for the complex programs. Orders to further stations and from other controls can be installed in the programs. Once the learning process of this module has been concluded, these learning steps can be transferred to the next module. As soon as all of the modules have been processed individually, the modules can be interconnected and the programs can be adapted. A complete production process can be simulated. This is an ideal training area for the professional practice of mechatronis, as well as all of the technical ranges (mechanical, electrical and pneumatic processes) are represented in a simple and clearly way, concerning each one of the modules and the complete system. Festo Didactic GmbH & Co.KG. FMS100 11

12 Introduction 3.4 Scope of tasks of the stations The stations are possessing a varied range of functions. A small extraction of the various possibilities of the stations follows Mechanics Obtaining basic mechanical skills about the assembly of basic modules Obtaining complex mechanical skills about the assembly of a complete station or complex modules Assembly provides instructions about the technical connections between the various components Pneumatics Understanding of a pneumatic circuit by set-up and pipe connection of the cylinders and valves Electrics Obtaining electrical knowledge of reading a circuit diagram, concerning the wiring of sensors and valves Functional understanding of the individual modules e.g. in case of error detection, by means of a circuit diagram and a measuring device Informatics Understanding of programs receiving an insight by controlling the individual components of the programs Changing and improving programs recognising and removing errors in a complete program Writing new programs new programs can be written by combination of the skills obtained in the steps before Bus technology Instructions in the various bus technologies avoidance to gain intimate knowledge about the various bus technologies is made impossible by working with the programs 12 Festo Didactic GmbH & Co.KG. FMS 100

13 4 General safety instructions 4.1 Use according to regulations This installation has been developed and produced exclusively for training purposes in the fields of automation and communication. The training company, as well as the instructors have to ensure, that the trainees pay strict attention to the safety precautions, as described in the accompanying manuals. Festo Didactic accepts no liability charges for possible damages to any trainee of the training company and/or further third parties, which might occur during use/operation of the installation, if it is not part of a real training situation; except Festo Didactic caused such damages deliberately or by negligence. Due to the product liability law and various EC-directives, the following directions are required and are to be strictly observed by the operator. 4.2 Handling the system Dangers in handling the machine The installation has been constructed technologically up to date and in conformance with the recognised rules of safety engineering. Nevertheless, during operation it is possible that harm might be caused to the user or third parties or that the installation or other property might get damaged. Therefore, the installation has to be handled according to specified operational use in perfect technical condition only. Safety endangering malfunctions can not be tolerated during training and have to be removed immediately. Note the danger area of the hydraulic press. This area may have to be especially marked and secured. The press always operates on high pressure. Danger of contusion! Note the danger area of the servo pneumatic. This area may have to be especially marked and secured The servo pneumatic moves with very high speed and considerable force. Extreme danger of contusion and impact! Any of the axles may be moved under the strictest precautions only. Moving the servo axles too fast may result in voltage induction, which would destroy the performance part of the axles. Festo Didactic GmbH & Co.KG. FMS

14 General safety instructions Safety precautions in standard operation Put the installation into operation only, once all of the protection settings are completely functional. At least, before starting operation, check the installation for externally visible damages and for the reliability of the safety devices. Do not grip into the installation while in operation. Before circuit construction, circuit disassembly and circuit modification: switch off air pressure and power supply. General safety regulations are to be observed: DIN and VDE Dangers due to electric current As soon as maintenance is completed, check the function reliability of the safety devices. Only trained experts in electric or electronic engineering are permitted to carry out work on the electric supply system. The terminal boxes are to be kept closed at all times. Access must be permitted only under supervision of a member of the training staff. Do not activate electric limit switches manually during fault search. Tools are to be used. Only low voltage 24VDC is to be used. 14 Festo Didactic GmbH & Co.KG. FMS 100

15 General safety instructions Dangers due to pneumatic energy Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt air pressure supply immediately. Caution! When the air pressure supply is activated, cylinders may move in or out. Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In this case, keep on holding the end of the tube. Do not exceed the permitted operating pressure. See data sheets Maintenance Servicing Malfunction removal Carry out adjustments and inspections as instructed, in accordance with the specified intervals. Secure the compressed air and electricity supplies to prevent unintentional start-up. During inspections, maintenance and repair work, the machine must be deenergised, de-pressurised and secured against unexpected restart. All screw connections released during maintenance, inspection or repair work must be checked to ensure correct re-tightening Organisational measures All existing safety devices must be checked at regular intervals. Festo Didactic GmbH & Co.KG. FMS100 15

16 General safety instructions 4.3 Personnel Notes on personnel Basically two situations have to be considered, concerning matters on personnel. Activities during training operations Activities outside training operations Training operations Trainees are permitted to work with the machine only under strict supervision of an experienced person or an instructor. Activities of trouble-shooting and fault correction are to be checked by the instructor. Special care should be taken regarding safety aspects Outside training operations Activities in the areas of maintenance, service and repair are to be carried out by only persons with appropriate technical qualifications. 16 Festo Didactic GmbH & Co.KG. FMS 100

17 General safety instructions Safety symbols In this manual the following danger designations and signs are being used: This symbol indicates an immediate threat to a persons health or life. DANGER! Failure to pay attention to this symbol may result in serious health damage, which may even lead to life-threatening injuries. This symbol emphasises important information for correct machine handling. IMPORTANT Failure to pay attention to this symbol may result in damages to the machine or to its surroundings. This symbol indicates operational tips and especially useful directions. i INFORMATION This symbol assists you to make optimal use of all of your machine s functions. Festo Didactic GmbH & Co.KG. FMS100 17

18 General safety instructions 18 Festo Didactic GmbH & Co.KG. FMS 100

19 5 Commissioning 5.1 Transport i Care is to be taken that the transport of the stations is to be executed only by a suitable transport vehicle. The weight amounts up to 500 kg, depending on the station. The route of transport is to be cleared in advance, to be accessible to the transport vehicle. Installation of warning signs or barriers may be required. The transport boxes are to be opened with care, as additional components, such as computers may be contained in the delivery, which are to be protected from falling out. Once the transport box has been opened and the possibly contained additional components removed, the station can be taken out to be transported to its destination by means of two fork-lifts or one fork-lift truck. Please check the stability of all of the profile connectors by means of an Allen key size 6. The connectors may have come loose during transport, due to inevitable vibration. Pay special attention to all overhanging components. Sensors and similar small parts are very easily damaged in case of improper transport. The stations are not to be picked up by or even under the mounted feet increased risk of becoming trapped or contused. Festo Didactic GmbH & Co.KG. FMS

20 Commissioning 5.2 Set up General information The installation is to be set up in a frost-free room with maximum relative air humidity of 70%. In countries with an atmospheric humidity over 70% and temperatures above 25 degrees Celsius, the premise is to provide an air-conditioning system for constant surrounding conditions. To comply with the levels of the regulatory guidelines, sources of electrical interference such as welding plants, large motors and contactors are to be checked for electromagnetic compatibility in advance and screened where necessary. To ensure faultless operation a load-bearing floor is required to avoid settling. Allow sufficient distance between the installation and the wall of the room. Any dust originating from construction work has to be kept off the installation (by covering) Set-up of the hydraulic station The hydraulic station is set up in its final position, at operating position 4. The installation is adjusted, by means of a spirit level, to a plate height of 785mm, by means of the adjustable feet. In case of very uneven ground, it may be necessary to underlay the adjustable feet. The next step is to mount the mounting brackets onto the square, which enable relative exact positioning with the transport system. The screws of the mounting brackets and the lock nuts of the adjustable feet are to be tightened firmly. The hydraulics may require to be filled up with oil. The transfer position at operating position 4, for the palette and work-piece, may require to be retaught. 20 Festo Didactic GmbH & Co.KG. FMS 100

21 Commissioning For a more simple room planning the complete installation design is shown in the following. The hydraulic station is to line up that a fault-free workpiece handing over can take place. Installation design FMS system Festo Didactic GmbH & Co.KG. FMS100 21

22 Commissioning Dimension drawing FMS 100 Position hydraulic station 22 Festo Didactic GmbH & Co.KG. FMS 100

23 Commissioning 5.3 Commissioning Commissioning of the system can ensue only, once all of the stations are connected to their definite position. The hydraulic station has to be mounted on operating position 4 of the transport system, utilising the included profiles. At this point, screw and lean the profiles lightly onto the basic frame of the transport system, by means of the angles. Align the hydraulic station by means of a spirit-level and tighten the connector profiles afterwards. It may be possible, that the transfer position of operating position 4 must be taught corrected Pneumatic commissioning The mechanical construction must be finished. At the beginning the stations have to be attached to the pneumatic system of the room. In most cases the maintenance unit is on the profile plate of the station. The coupling has a 5 mm nominal diameter. If the available system is equipped with 7.9 mm nominal diameter, it is possible to change the coupling of the maintenance unit with a greater one. (reducer 1/8 on 1/4 necessary). If this has been carried out, the stations can be provided with 6 bar and the pneumatic commissioning is realised Electric commissioning The station must be provided with electrical voltage now. The control cabinets are provided with a voltage of 230 V. The delivered cable has a completely protected norm plug, this must be plugged into an electrical socket protected sufficiently. Distribution strips are, enclosed to this also for the connection of other stations. If an extension for the cable is necessary for the distribution strip, this can to be executed only by a trained expert. The electrical socket must be protected, corresponding to the customer. The power supply (24 VDC) of the sensoric and the actuators of the station is provided in each case by means of a 2-pin cable. The voltage supply is a 24 V power supply unit, contained in the control cabinet or somewhere in the station. Some of the stations are provided with a voltage of 380 V. The enclosed cable has a completely protected norm plug, this must be plugged into an electrical socket protected sufficiently. If an extension for the cable is necessary for the distribution strip, this can to be executed only by a trained expert. The electrical socket must be protected, corresponding to the customer. Festo Didactic GmbH & Co.KG. FMS100 23

24 Commissioning Connecting communication cables Profibus with S7 The communication ensues by means of profibus, should the station be connected to another station, as described under the point complete process, for example. The data cable is plugged onto the profibus card of the control, at the interface marked above. The cable leads from the second interface to the controls of further stations. T-connectors are required for transmission to the next station, as the Profibus card (CP 343 5) possesses one interface only. 24 Festo Didactic GmbH & Co.KG. FMS 100

25 Commissioning 5.4 Start up the system Start up conditions For the FMS system a first commissioning at Festo was already executed. The following explanation is for the commissioning at customer s side. Before starting the cell control, the work-pieces already have to be positioned on the conveyor belt of the transport system. For the work-piece carriers it is important: Not to stand in any operating position All of them, one after another Frontally of the vision station Max. 10 carrier This start-up situation applies to each production start-ups and is to be re-entered at each production start-up. It is required, that all of the stations are set up, aligned and adjusted, before starting the system. All of the transfer and assembly positions have to be adjusted or taught. The first start-up and teaching of each station is explained in detail in the station s manual and has to be executed before general information Switch on distribution strips Activate air supply for all stations min. 4 bar max. 6 bar Activate master switch of the AS/RS station AUTO/MAN switch on AUTO Activate Power supply unit of soldering station AUTO/MAN switch on AUTO Activate power supply unit of the robot assembly station AUTO/MAN switch on AUTO Activate power supply unit of hydraulic station AUTO/MAN switch on AUTO activate hydraulic aggregate Activate distribution strip of CNC-coupling station AUTO/MAN switch on AUTO Do not activate the key switches of the CNC machines and the master switch of the robot Unlock the emergency-off switch of all of the stations and confirm with the QUIT button. Confirm Emergency board of CNC-coupling station with key switch Switch on the PC - COSIMIR CONTROL The switch of the teach-box of the robots is to be set to Disable. Activate the master switch of the CNC machines and the Drive units, once all of the controls have been started up. Switch on PC s of CNC-machines WIN NC is started automatically The key actuators of the CNC machine is to be set to FMS mode. Festo Didactic GmbH & Co.KG. FMS100 25

26 Commissioning Adjust AS/RS station Danger of collision. In case the transfer handling is very close to or in imminent danger of collision with the transport system station, it is to be moved out of the danger area manually. The axis are to be moved very slowly only, otherwise voltage induction may occur. If a palette is positioned in the transfer unit, it has to be removed. The selector switch has to be in auto-mode If the RESET lamp is flashing, start the adjustment operation by using the RESET button. If the AUTOMATIC ON lamp is flashing, use the AUTOMATIC ON button to activate the station s automatic mode Soldering station Danger of collision. The arm of the robot has to be removed from any danger area of the CNC machine. Possibly existing palettes and work-pieces have to be removed. The grippers have to be available at their place of destination. The cleaning sponge of the soldering tip should be humid (not wet). Sufficient soldering zinc has to be available. The magazines have to be stocked up. Activate the controller of the soldering system. The soldering iron requires approx. 1 min. to reach its operating temperature. Switch on robot drive unit Start the adjustment operation by using the RESET button. Use the AUTOMATIC ON button to activate the station s automatic mode Robot assembly station Danger of collision. In case the robot is very close to or in immediate danger of collision, the robot (robot-arm) is to be removed manually from the danger area. Possibly existing palettes and work-pieces have to be removed. The magazines are to be stocked up. Switch on robot drive unit Start the adjustment operation by using the RESET button. Use the AUTOMATIC ON button to activate the station s automatic mode. 26 Festo Didactic GmbH & Co.KG. FMS 100

27 Commissioning Hydraulic station Danger of injury. Work-pieces or alien elements possibly existing in the hydraulic press have to be removed after conclusion of the adjustment process, only. Possibly existing palettes have to be removed. The hydraulic aggregate has to be activated. The hand levers have to be set to the setting store. Start the adjustment process by using the RESET button. Possibly existing palettes have to be removed. Use the AUTOMATIC ON button to activate the station s automatic mode Adjust transport system The transport system does not require a special adjustment mode. Before start-up by COSIMIR CONTROL, the work-piece carriers are to be positioned onto the transport system, as described in the introduction of this chapter. No work-pieces have to be positioned in the work-piece receptions. The start of the transport system is carried out by the hydraulic station. Festo Didactic GmbH & Co.KG. FMS100 27

28 Commissioning CNC-coupling station Danger of collision. The linear axis of the CNC station moves to the commission table. Danger of collision. The arms of the robot have to be removed from any danger area of the CNC machine. Before starting the adjustment process, work-pieces remaining in the testing station or in the vice of the processing machine have to be removed. If power is available, turn the emergency key switch on the operation panel to position 1 and back to position 0. The emergency circuit is confirmed. Start up CNC-machines: switch on both PC s Turn key switches of both machines to position 1 and FMS-Mode Start the adjustment process by using the RESET button. Use the START button to activate the station s automatic mode Vision station Danger of collision. In case the robot is very close to or in immediate danger of collision, the robot (robot-arm) is to be removed manually from the danger area. Possibly existing palettes and work-pieces have to be removed. Activate the controller of the vision system. Start the adjustment process by using the RESET button. To set the station to automatic mode activate AUTOMATIC ON button Start up cell control and COSIMIR CONTROL Start up cell control. Double click COSIMIR CONTROL icon Once the COSIMIR CONTROL picture display appears, a project can be chosen. Under File you can choose the project C:\ProgramFiles\COSIMIRCONTROL\Projects\Marmara\Marmara.lpj Change to production (See chapter START UP COSIMIR CONTROL in this manual) 28 Festo Didactic GmbH & Co.KG. FMS 100

29 Commissioning Start-up of processes At this point all of the stations are in automatic mode and fully operational. Existing or newly created processes can be started by means of the cell control. The creation of processes is described in detail in the station s manual. 5.5 Shut down the system To shut down the system its necessary to proceed as follows: Stop production of COSIMIR CONTROL Shut down COSIMIR CONTROL software Shut down windows and switch of PC. (press power button min. 3 sec.) Shut down the CNC-software at the CNC-machines with ALT + F4 Shut down windows Switch off main switch CNC-machines Switch off Mitsubishi Drive Units Press EMERGENCY button at all other stations Switch off all main switches Switch off all distribution stripes Festo Didactic GmbH & Co.KG. FMS100 29

30 Commissioning 30 Festo Didactic GmbH & Co.KG. FMS 100

31 6 Operation This chapter describes the necessary control units for starting and stopping the system, as well as operating with the system. 6.1 General operation notes The stations require some rules of operation witch should be observed. If they are not complied, faults in the processes are possible. Dangers for the physical health also cannot be excluded. It is recommended to observe the following rules strictly Behaviour rules During the operation of the stations it is forbidden to grip in by hand. With larger audience a mechanical protection of the stations is necessary. Removing any cable under tension is forbidden. Water has to be kept away from the plant Operation rules The stations only may be used by introduced persons. The operation has to be carried out according to the operating instructions. A pushing the different switches/push buttons of all control units uncheckedly has to be stopped. No workpiece carriers may be taken by the system. Festo Didactic GmbH & Co.KG. FMS

32 Operation 6.2 Process description Hydraulic station The installation has been designed to produce an electronic handheld device. The handheld device is divided up into the following three types Type 1 => Roulette 1 Type 2 => Roulette 2 Type 3 => Roulette 3 The hydraulic station has the task to press the device, for which no special components are required. In automatic mode process 408 a palette with 2 assembled handheld devices is placed onto the hydraulic station. Sub-process 408 compresses the pre-assembled handheld devices. 3 different types are available. Handheld device type 1 / Roulette serves as an example. A palette 2PCB with two pre-assembled handheld devices is transferred from the AS/RS station to the transport system, from where the palette is transported to the hydraulic press station (operating position 4) for clamping. The transfer handling takes the palette off the work-piece carrier and places it onto palette position 1. The work-piece carrier is re-released. The first handheld device is retrieved from position 11 to be placed onto the reception. The safety door of the press is being opened up and the work-piece moves into the press. The safety door is being closed. The pins are pressed into the lower housing part, thus concluding the assembly handling. After conclusion of the pressing process, the safety door of the press is opened up to enable the handheld device to move out of the press. The transfer handling retrieves the handheld device and returns it to the retrieval position. According to the same sequence ensues the processing of the second handheld device. Once both of the handheld devices have been pressed, a work-piece carrier is being requested. Once the work-piece carrier has been clamped into operating position 4, the palette is placed onto the waiting work-piece carrier. At this point the palette is stored for further use in the AS/RS station. 32 Festo Didactic GmbH & Co.KG. FMS 100

33 Operation General information The task of the FMS system is to produce an electrical handheld device. The installation has been designed for three different types of handheld devices. But only type 1 Roulette is being integrated and programmed in an instant. The production of a Roulette can be realised by the application of various subprocesses. The following example describes a complete assembly process of a handheld device. A palette, containing two raw lower housing parts, is retrieved from the AS/RS station and transported to the CNC station, where the basic bodies are processed inside the CNC milling machine, one after another. The processed work-pieces are returned to the AS/RS station for further use. The processing of the upper housing parts is identical to that of the lower parts, but processing of the pins ensues in the CNC turning machine. The printed circuit boards receive soldering before their assembly. In the soldering station, they are equipped with a battery clip, which is soldered on by a soldering robot. At this point, all of the required components are available. The palettes, containing the components, are retrieved from the AS/RS station and transferred to the assembly station, where a lower housing part is placed into the assembly device. The printed circuit board is inserted into the lower part. A battery is retrieved from the battery magazine and inserted into the battery clip of the printed circuit board. Now, the upper housing part is placed onto the lower part. The housing parts are fixed to another by means of the pressing pins, inserted in the end. Once both of the handheld devices are assembled, they are transported to the hydraulic station to receive pressing, one after the other. At this point, the handheld device is completely assembled and stored in the AS/RS station for commissioning. Festo Didactic GmbH & Co.KG. FMS100 33

34 Operation 6.3 Order codes Hydraulic station Servo-pneumatic feeder PLC-COSIMIR CONTROL Station Ordernumber/ Orderdescription 16 # 4500 Move palette from source position to target position Type / Parameter Parameter 1 Palette source position Parameter 2 Palette target position Nr. Description Available 1 Palette place 1 X 2 Palette place 2 X 15 Conveyor pickup/place position X 1 Palette place 1 X 2 Palette place 2 X 15 Conveyor pickup/place position X Parameter 3 Return code 0 No errors X 1 No pallet at source position X 2 Target position occupied X 14 Error servo pneumatic X 15 Run-time error X Invalid input parameters x Station Ordernumber/ Orderdescription Type / Parameter Nr. Description Available 16 # 4501 Move housing from source to target position Parameter 1 Workpiece source position 11 Palette 1 position 11 X 12 Palette 1 Position 12 X 16 Press feeding position X 21 Palette 2 position 21 X 22 Palette 2 Position 22 X Parameter 2 Parameter 3 Return code 0 No errors X 1 No pallet at source position X 2 Error servo pneumatic X 15 Run-time error X Invalid input parameters X 34 Festo Didactic GmbH & Co.KG. FMS 100

35 Operation Station Ordernumber/ Orderdescription Type / Parameter Nr. Description Available 16 # 4502 Parameter 1 Reset SPC 200 Parameter 2 Parameter 3 Return code 0 No errors x 14 Error servo pneumatic X 15 Run-time error X Invalid input parameters x 6.4 Order codes Hydraulic station press PLC-COSIMIR CONTROL Station Ordernumber/ Orderdescription 16 # 4600 Start hydraulic press Type / Parameter Parameter 1 Parameter 2 Parameter 3 Return code Nr. Description Available 0 No errors X 1 No workpiece in press X 2 Press not in init position X 3 Lower sensor is reached before press pressure is reached X 4 After pressing no workpiece in feeding position available X 15 Run-time error X Invalid input parameters X Festo Didactic GmbH & Co.KG. FMS100 35

36 Operation 6.5 Control strip hydraulic station The robot assembly station is controlled by means of the control strip shown below, which is located at the top of the switchgear cabinet. Operating strip Name Element Function Automatic on H5 Flashing Lights up Request press start Automatic active S5 Start automatic Automatic off H6 Flashing Stop automatic at cycle end S6 Stop automatic at cycle end Reset H7 Flashing Lights up Request press reset Reference move ready S7 Start reference move Confirm H8 Flashing Announce error S8 Confirm error Mode H9 Choose mode Position 0 Position 1 Automatic mode Teach/ manual mode Teach mode H9 Announce teach mode Controller off H1 Announce controller off Controller off S2 Switch off controller Controller on H3 Flashing Lights up Request press controller on Controller on S3 Switch on controller Emergency stop S1 Emergency stop 36 Festo Didactic GmbH & Co.KG. FMS 100

37 Operation The following actions can be executed from the control strip: Activating automatic mode for networked operation Deactivating networked operation Starting an testing cycle with the Auto on button (without networking) Resetting the station (reference move) Controller off CONTROLLER ON KEY SWITCH MODE = 0 Waiting for RESET (Reset lamp flashes) Pushbutton RESET Waiting for a) AUTO ON or b) STAND ALONE MODE Key switch MODE = 0 and pushbutton AUTO ON Key switch MODE = 1 Waiting for a) ORDER FROM SCADA or b) AUTOMATIC OFF Pushbutton AUTO OFF Order from SCADA Preset editor for material selection for stand alone mode START ASSEMBLY STAND ALONE MODE AUTOMATIC ON Assembly sequence active (Started by SCADA) Assembly sequence active (Started by SCADA) INITIAL POSITION INITIAL POSITION Operating menu structure Festo Didactic GmbH & Co.KG. FMS100 37

38 Operation 6.6 Reset mode The first start-up of the station is to be completed before the station can be adjusted. Retrieve partly processed work-pieces, if required. Clear palette places for the transfer. Hydraulic oil, electrical current and air are to be available. The danger areas of the axle and the press are to be cleared. All of the emergency-off switches are to be unlocked. Set selector switch (key actuator) AUTO/MAN to AUTO. After activating the supply voltage, the lamp CONTROL OFF lights up. Press the key CONTROL ON. (Take note that the EMERGENCY OFF mushroom actuator is unplugged. Unplug and acknowledge, if necessary.) The lamp CONTROL OFF switches off. Illuminated push-button RESET flashes with ca 0,5 Hz. Start the adjustment operation by using the RESET button. Station approaches reference point. If the illuminated push-button Confirm is lit with 2 HZ, not all of the work-piece or palette positions required for the assembly are cleared. Once the work-pieces or palettes have been retrieved, the adjustment process can be continued by pressing the illuminated push-button Confirm. Once the basic position has been reached, the illuminated push-button RESET lights up to indicate the basic position. At this point the illuminated button AUTOMATIC ON flashes as an input request for the start signal. 6.7 Automatic mode Once it has been successfully reset, the station is ready for the start signal to activate automatic mode. This is indicated by the start button flashing (prompt for entry). Reset Lamp lights. The control of all of the danger areas has to be concluded Activating automatic mode and starting the process with network Set the key switch to mode 0 for automatic mode with network, press the AUTOMATIC ON illuminated pushbutton. AUTOMATIC ON lamp lights up Till now the order processing is done by COSIMIR CONTROL. The communication between the workcell controller and all stations works with precisely orders. The table contents all executable orders for every station. 38 Festo Didactic GmbH & Co.KG. FMS 100

39 Operation Automatic start up The following serves as an example of a complete automatic process: Retrieve palette with 2 pre-assembled handheld devices from the AS/RS station. Transport palette to operating position 4 (hydraulic press station). Transfer palette from the transport system (position 0) into the hydraulic press station onto palette place 1. Release work-piece carrier. Retrieve handheld device from position 11 for placement in the reception module. Open safety door of the press. Move work-piece into press and close the safety door. Upper and lower housing parts are to be compressed by means of the pins. Open safety door and return the handheld device to its retrieval place. Assemble the second handheld device. Request work-piece carrier, once both of the handheld devices have been pressed. Store palette on work-piece. Return palette to AS/RS station. Store palette in AS/RS station Automatic stop The illuminated push-button AUTOMATIC OFF is to be pressed. The processes in progress are concluded at the end of the cycle. The illuminated push-button START flashes during the remaining running time, up to the end of the cycle. After the end of the cycle, automatic mode is off and the status is the same as after the reset mode. Festo Didactic GmbH & Co.KG. FMS100 39

40 Operation 6.8 Manual mode Manual start-up The course of the manual mode is identical to the automatic mode. In this case, the work-pieces are not taken from the transport system. The palette requires to be placed manually onto the palette reception, whereupon the process run continues on its own. Once the hydraulic station has been adjusted successfully, it is ready for the start-up in manual mode. The start-up request is indicated by the flashing push-button actuator START and the continuous light of the push-button actuator RESET. The key actuator AUTO/MAN requires to be set to position MAN (1). Place palette with 2 pre-assembled handheld devices onto palette place 1. At this point, press the illuminated push-button AUTOMATIC ON Whereupon the lamp AUTOMATIC ON is to light up. Retrieve handheld device from position 11 and place it into the reception module. Open safety door of the press. Move work-piece into the press and close safety door. Compress upper and lower housing part by means of the pins. Open safety door and return the handheld device to the retrieval place. Assemble the second handheld device. Conclude manual mode Manual stop The illuminated push-button AUTOMATIC ON is to be pressed. The processes in progress are concluded at the end of the cycle. The illuminated push-button START flashes during the remaining running time, up to the end of the cycle. After the end of the cycle, automatic mode is off and the status is the same as after the reset mode. 40 Festo Didactic GmbH & Co.KG. FMS 100

41 Operation 6.9 Teach mode The teach-mode is responsible for storing the various positions. The winpisa-manual explains the teaching of the servo axles in detail. Principally, all of the positions available to the servo axle can be taught. Festo Didactic GmbH & Co.KG. FMS100 41

42 Operation 42 Festo Didactic GmbH & Co.KG. FMS 100

43 7 Technology This chapter refers to the technology of the robot assembly station. For better construction understanding of the station, the technical drawings should be a very helpful data. The rooms must be checked for their technical datas before built up the station/system. The size of the door openings and the entrance must be big enough for the measurements of the system. Even the load-capacity of the floor must be high enough for the system. 7.1 drawings Technical drawing hydraulic station Festo Didactic GmbH & Co.KG. FMS

44 Technology Module positions hydraulic station 44 Festo Didactic GmbH & Co.KG. FMS 100

45 Technology 7.2 Modules in use The robot assembly station is made up of a number of different function modules. Pallet reception Transfer unit Servo positioning axis Hydraulic press Assembly device Palette reception The palette reception accommodates one palette with two handheld devices, assembles and equipped with pins. 2 of these receptions are available. Palette reception Performance Inputs 2 Outputs 0 Max. reservation 1 hendheld/reception Festo Didactic GmbH & Co.KG. FMS100 45

46 Technology Transfer unit The palettes with the handheld devices are gripped by the transfer unit to be placed either onto the palette receptions or the work-piece carrier. Transfer unit Performance Inputs 6 Outputs 6 Max. reservation 1 Palette / 1 hendheld 46 Festo Didactic GmbH & Co.KG. FMS 100

47 Technology Servo positioning axle The servo axle moves the palettes to the various placement positions. Housing upper part magazine Performance Inputs Controlled via SPC- Controller Outputs 2 Max. reservation 1 Palette / 1 hendheld Festo Didactic GmbH & Co.KG. FMS100 47

48 Technology Hydraulic press At this point the handheld devices, assembled and provided with pins, are compressed with each other. Hydraulic press Performance Inputs 6 Outputs 5 Max. reservation 1 hendheld 48 Festo Didactic GmbH & Co.KG. FMS 100

49 Technology Assembly device The handheld devices are moved into the press by this device to receive pressing afterwards. Assembly device Performance Inputs 3 Outputs 2 Max. reservation 1 hendheld Festo Didactic GmbH & Co.KG. FMS100 49

50 Technology 7.3 Workpiece positions Position arrangement 50 Festo Didactic GmbH & Co.KG. FMS 100

51 Technology Transport direction work piece carrier The positional specifications on the palettes depend on the amount of palettes. The first number indicates the palette number, the second number indicates the position number of the respective palette. For example: This way the palette holder no.1 receives the position numbers and the palette holder no.2 the position numbers a.s.o. 7.4 Technical datas Pos. Designation / Criterion Measurements / Feature 1 Width 700 mm 2 Max. width 700 mm 3 Length mm 4 Max. length mm 5 Plate hight 785 mm 6 Min. plate hight 770 mm 7 Max. plate hight 790 mm 8 Station hight Approx mm 9 Weight Approx. 200 kg Festo Didactic GmbH & Co.KG. FMS100 51

52 Technology 52 Festo Didactic GmbH & Co.KG. FMS 100

53 8 Pneumatic With the help of pneumatic cylinders, axes and grabs, the workpieces and the workpiece carriers get clamped, distributed or just moved. The valve terminal necessary for the control, consist from different, the use purpose, individual valves. The cylinders and the valves are described in the following. 8.1 The valve terminal Example Valve terminal This valve terminal serves as an example. Pos. Name 1 Odernumber Ordername 10P-10-6B-IC-N-V-2M4J+HZ Festo Didactic GmbH & Co.KG. FMS

54 Pneumatic 8.2 Pneumatic supply The pressure in the supply line must not exceed 10 bar. A fine filter has to be installed, to prevent contamination by rust or similar. A stop cock is required for the supply of the installation. The pressure regulators should be set in between 5 and 6 bar. The filter and water separators require maintenance according to the instructions of the documentation of these components. The exact allocation of the valve terminal can be found in the pneumatic plan. Service unit 54 Festo Didactic GmbH & Co.KG. FMS 100

55 9 Electrical system To operate the system it is required to connect all of the supply cables and communication lines included. The cables used to program the system are explained additionally. To give you a better overview of the being lines used in the plant, these are explained in the following. 9.1 Power supply The devices are delivered together with the respective power supply plugs, protectively contact covered, in case they require power supply. The customer must ensure that the power supply is earthed correctly and is equipped with a fault current monitor. If it is required for several devices to be in operation at the same time, it is possible to connect these to a switchboard containing distribution board, provided that the permissible maximum rating is not exceeded. Each station contains its own individual EMERGENCY STOP switch, which at first reacts to its respective station only. It has to be clarified in advance, if a central ROOM EMERGENCY STOP switch is required. Festo Didactic GmbH & Co.KG. FMS

56 Electrical system 9.2 Controller The control of the hydraulic station is described in the following Controller design Siemens S7 No. Card location Module Name Comment 1 2 Controller CPU-314C 2 DP 3 Virtually occupied 2 4 Profibus card CP For external communication 3 5 Asi-card CP For external communication S7 controller hydraulic station The communication ensues by means of Profibus, should the station be connected to another station, as described under the point complete process, for example. Two possibilities are available to program the Siemens controls. A MPI cable is sufficient for programming, if a special programming unit is available. If a common PC is used for programming, a MPI card needs to be installed into the PC. If such a card containing PC is available, a common MPI cable may be used. A MPI cable inclusive adapter box is required, if a PC without MPI card is used for programming. The interface for programming is on the CPU314 Card. 56 Festo Didactic GmbH & Co.KG. FMS 100

57 Electrical system Controller design SPC200 No. Card location Name Comment 1 X2 PWR-AIF Supply module 2 X3 MMI-DIAG Diagnose module 3 X5 DP Profibus DP 4 X6 I/O I/O module SPC controller example The communication to the main control ensues by means of Profibus DP. The communication to the handling ensues by means of a CAN-Bus. See next drawing. Festo Didactic GmbH & Co.KG. FMS100 57

58 Electrical system Example SPC200 setup 58 Festo Didactic GmbH & Co.KG. FMS 100

59 Electrical system 9.3 Wiring The wiring within the station and the wiring to the other stations are explained in the following I/O-Components The operating strip, the modules from the profile plate and the z-axis are pluggable connected via I/O-terminals to the SM323 I/O-cards from the control. So that a perfect communication can be ensured, the I/O interface is standardized. The I/O terminal is at all work positions at the disposal. I/O-Terminal Technical data Plug type IEEE pins Inputs 8 Outputs 8 Current consumption Power supply Max. 1A/PIN 24 VDC Festo Didactic GmbH & Co.KG. FMS100 59