fms 100 manual hydraulic station - marmara...

FMS 100

Manual

Hydraulic station

2 © Festo Didactic GmbH & Co.KG. • FMS 100

Order-NR.:

Type: Manual FMS

Designation FMS100_Hydraulic_A001

Printed: 02.04.2003

Autor: Schober

Graphics: Schober

Layout: Schober

© Festo Didactic GmbH & Co.KG., D-73770 Denkendorf, 2003

Internet: www.festo.com/didactic

e-mail: [email protected]

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.

© Festo Didactic GmbH & Co.KG. • FMS100 3

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.

•

1 Intended use


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 60204 - Electrical equipment of industrial machines • DIN VDE 0113 - See DIN EN 60204 • DIN 40719 - Circuit documentation • VDI 2853 - Technical safety requirements concerning the building, equipping and

operation of industrial robots • VDI 2853 - Technical safety requirements concerning automated production

systems • VDI 2411 - Terms and explanations in conveying and handling • VDI 2860 - Assembly and robotics - terms • VDI 2861 - Assembly and robotics - characteristic quantities • DIN 19245 - 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(711-3467-0)

List of applicable standards and regulations

© Festo Didactic GmbH & Co.KG. • FMS 100 5

1 Intended use _____________________________________________________ 3

2 Contents_________________________________________________________ 5

3 Introduction______________________________________________________ 9

3.1 General______________________________________________________ 9

3.2 Hydraulic station _____________________________________________ 10

3.3 Didactic structure ____________________________________________ 11

3.4 Scope of tasks of the stations __________________________________ 12

3.4.1 Mechanics ______________________________________________ 12

3.4.2 Pneumatics _____________________________________________ 12

3.4.3 Electrics ________________________________________________ 12

3.4.4 Informatics______________________________________________ 12

3.4.5 Bus technology __________________________________________ 12

4 General safety instructions_________________________________________ 13

4.1 Use according to regulations ___________________________________ 13

4.2 Handling the system __________________________________________ 13

4.2.1 Dangers in handling the machine ____________________________ 13

4.2.2 Safety precautions in standard operation _____________________ 14

4.2.3 Dangers due to electric current _____________________________ 14

4.2.4 Dangers due to pneumatic energy ___________________________ 15

4.2.5 Maintenance – Servicing – Malfunction removal ________________ 15

4.2.6 Organisational measures __________________________________ 15

4.3 Personnel___________________________________________________ 16

2 Contents

Contents


4.3.1 Notes on personnel _______________________________________ 16

4.3.2 Training operations _______________________________________ 16

4.3.3 Outside training operations ________________________________ 16

4.3.4 Safety symbols __________________________________________ 17

5 Commissioning __________________________________________________ 19

5.1 Transport ___________________________________________________ 19

5.2 Set up______________________________________________________ 20

5.2.1 General information ______________________________________ 20

5.2.2 Set-up of the hydraulic station ______________________________ 20

5.3 Commissioning ______________________________________________ 23

5.3.1 Pneumatic commissioning _________________________________ 23

5.3.2 Electric commissioning ____________________________________ 23

5.3.3 Connecting communication cables___________________________ 24

5.4 Start up the system ___________________________________________ 25

5.4.1 Start up conditions _______________________________________ 25

5.4.2 general information_______________________________________ 25

5.4.3 Adjust AS/RS station______________________________________ 26

5.4.4 Soldering station _________________________________________ 26

5.4.5 Robot assembly station ___________________________________ 26

5.4.6 Hydraulic station _________________________________________ 27

5.4.7 Adjust transport system ___________________________________ 27

5.4.8 CNC-coupling station______________________________________ 28

Contents


5.4.9 Vision station____________________________________________ 28

5.4.10 Start up cell control and COSIMIR CONTROL ___________________ 28

5.4.11 Start-up of processes _____________________________________ 29

5.5 Shut down the system_________________________________________ 29

6 Operation_______________________________________________________ 31

6.1 General operation notes _______________________________________ 31

6.1.1 Behaviour rules __________________________________________ 31

6.1.2 Operation rules __________________________________________ 31

6.2 Process description___________________________________________ 32

6.2.1 Hydraulic station _________________________________________ 32

6.2.2 General information ______________________________________ 33

6.3 Order codes Hydraulic station Servo-pneumatic feeder PLC-COSIMIR CONTROL _________________________________________________________ 34

6.4 Order codes Hydraulic station press PLC-COSIMIR CONTROL _________ 35

6.5 Control strip hydraulic station __________________________________ 36

6.6 Reset mode _________________________________________________ 38

6.7 Automatic mode _____________________________________________ 38

6.7.1 Activating automatic mode and starting the process with network _ 38

6.7.2 Automatic start up________________________________________ 39

6.7.3 Automatic stop __________________________________________ 39

6.8 Manual mode________________________________________________ 40

6.8.1 Manual start-up __________________________________________ 40

6.8.2 Manual stop_____________________________________________ 40

Contents


6.9 Teach mode _________________________________________________ 41

7 Technology _____________________________________________________ 43

7.1 drawings ___________________________________________________ 43

7.2 Modules in use ______________________________________________ 45

7.2.1 Palette reception _________________________________________ 45

7.2.2 Transfer unit ____________________________________________ 46

7.2.3 Servo positioning axle_____________________________________ 47

7.2.4 Hydraulic press __________________________________________ 48

7.2.5 Assembly device _________________________________________ 49

7.3 Workpiece positions __________________________________________ 50

7.4 Technical datas ______________________________________________ 51

8 Pneumatic ______________________________________________________ 53

8.1 The valve terminal ____________________________________________ 53

8.2 Pneumatic supply ____________________________________________ 54

9 Electrical system _________________________________________________ 55

9.1 Power supply ________________________________________________ 55

9.2 Controller ___________________________________________________ 56

9.2.1 Controller design Siemens S7_______________________________ 56

9.2.2 Controller design SPC200 __________________________________ 57

9.3 Wiring______________________________________________________ 59

9.3.1 I/O-Components _________________________________________ 59


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.

3 Introduction

3.1 General

Introduction


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.

3.2 Hydraulic station

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Introduction


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.

3.3 Didactic structure

Introduction


The stations are possessing a varied range of functions. A small extraction of the various possibilities of the stations follows.

3.4.1 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

3.4.2 Pneumatics

• Understanding of a pneumatic circuit by set-up and pipe connection of the cylinders and valves

3.4.3 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

3.4.4 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.

3.4.5 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

3.4 Scope of tasks of the stations


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.

4.2.1 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.

4 General safety instructions

4.1 Use according to regulations

4.2 Handling the system

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General safety instructions


4.2.2 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 58126 and VDE 0100.

4.2.3 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.



4.2.4 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.

4.2.5 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 de-energised, 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.

4.2.6 Organisational measures

All existing safety devices must be checked at regular intervals.



4.3.1 Notes on personnel

Basically two situations have to be considered, concerning matters on personnel.

• Activities during training operations • Activities outside training operations

4.3.2 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.

4.3.3 Outside training operations

Activities in the areas of maintenance, service and repair are to be carried out by only persons with appropriate technical qualifications.

4.3 Personnel



4.3.4 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.


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.

5 Commissioning

5.1 Transport

i

Commissioning


5.2.1 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).

5.2.2 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.

5.2 Set up

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

Commissioning


Dimension drawing FMS 100

Position hydraulic station

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.

5.3.1 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.

5.3.2 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.

5.3 Commissioning

Commissioning


5.3.3 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.

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Commissioning


5.4.1 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.

5.4.2 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.

5.4 Start up the system

Commissioning


5.4.3 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.

5.4.4 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.

5.4.5 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.

Commissioning


5.4.6 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.

5.4.7 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.

Commissioning


5.4.8 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.

5.4.9 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.

5.4.10 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)

Commissioning


5.4.11 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.

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

5.5 Shut down the system

Commissioning



This chapter describes the necessary control units for starting and stopping the system, as well as operating with the system.

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.

6.1.1 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. 6.1.2 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.

6 Operation

6.1 General operation notes

Operation


6.2.1 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.

6.2 Process description

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Operation


6.2.2 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 sub-processes. 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.

Operation


Station

Ordernumber/ Orderdescription

Type /

Parameter

Nr. Description Available

1 Palette place 1 X

2 Palette place 2 X

Parameter 1

Palette source

position 15 Conveyor pickup/place position X

1 Palette place 1 X

2 Palette place 2 X

Parameter 2

Palette target

position 15 Conveyor pickup/place position X

Parameter 3

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

16 # 4500

Move palette from

source position to

target position

Return code

65535 Invalid input parameters x

Station


Type / Parameter


11 Palette 1 position 11 X

12 Palette 1 Position 12 X

16 Press feeding position X

21 Palette 2 position 21 X

Parameter 1

Workpiece

source position

22 Palette 2 Position 22 X

Parameter 2

Parameter 3

0 No errors X

1 No pallet at source position X


15 Run-time error X

16 # 4501

Move housing

from source to

target position

Return code

65535 Invalid input parameters X

6.3 Order codes Hydraulic station Servo-pneumatic feeder PLC-COSIMIR CONTROL

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Operation


Station


Type /

Parameter


Parameter 1

Parameter 2

Parameter 3

0 No errors x


15 Run-time error X

16 # 4502

Reset SPC 200

Return code

65535 Invalid input parameters x

Station


Type / Parameter


Parameter 1

Parameter 2

Parameter 3

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

16 # 4600

Start hydraulic

press Return code

65535 Invalid input parameters X

6.4 Order codes Hydraulic station press PLC-COSIMIR CONTROL

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Operation


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

Flashing Request press „start“ H5

Lights up Automatic active Automatic on

S5 Start automatic

H6 Flashing Stop automatic at cycle end Automatic off

S6 Stop automatic at cycle end

Flashing Request press “reset” H7

Lights up Reference move ready Reset

S7 Start reference move

H8 Flashing Announce error Confirm

S8 Confirm error

Position 0 Automatic mode Mode H9 Choose mode

Position 1 Teach/ manual mode

Teach mode H9 Announce teach mode

Controller off H1 Announce controller off

Controller off S2 Switch off controller

Flashing Request press „controller on“ H3

Lights up Controller on Controller on

S3 Switch on controller

Emergency stop S1 Emergency stop

6.5 Control strip hydraulic station

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 SWITCHMODE = 0

PushbuttonRESET

Waiting for (Reset lamp flashes)

RESET

Waiting fora) AUTO ONorb) STAND ALONE MODE

Waiting fora) FROM SCADAorb)

ORDER

AUTOMATIC OFF

Key switch

and pushbuttonMODE = 0

AUTO ON

Preset editorformaterial selectionfor stand alone mode

Key switchMODE = 1

Assembly sequence active(Started by SCADA)

Order fromSCADA

PushbuttonAUTO OFF

INITIALPOSITION

INITIALPOSITION

Assembly sequence active(Started by SCADA)

START ASSEMBLYSTAND ALONE MODEAUTOMATIC ON

Operating menu structure

Operation


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.

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.

6.7.1 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.

6.6 Reset mode

6.7 Automatic mode

Operation


6.7.2 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.

6.7.3 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.

Operation


6.8.1 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.

6.8.2 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.

6.8 Manual mode

Operation


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.

6.9 Teach mode

Operation



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.

Technical drawing hydraulic station

7 Technology

7.1 drawings

Technology


Module positions hydraulic station

Technology


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

7.2.1 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

7.2 Modules in use

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Technology


7.2.2 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

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Technology


7.2.3 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

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Technology


7.2.4 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

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Technology


7.2.5 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

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Technology


Position arrangement

7.3 Workpiece positions

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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 11-14 and the palette holder no.2 the position numbers 21-24 a.s.o.

Pos. Designation / Criterion Measurements / Feature

1 Width 700 mm

2 Max. width 700 mm

3 Length 1 800 mm

4 Max. length 1 800 mm

5 Plate hight 785 mm

6 Min. plate hight 770 mm

7 Max. plate hight 790 mm

8 Station hight Approx. 1600 mm

9 Weight Approx. 200 kg

7.4 Technical datas

Technology



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.

Example Valve terminal

This valve terminal serves as an example.

Pos. Name

1 Odernumber 18 200

2 Ordername 10P-10-6B-IC-N-V-2M4J+HZ

8 Pneumatic

8.1 The valve terminal

Pneumatic


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

8.2 Pneumatic supply


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.

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.

9 Electrical system

9.1 Power supply

Electrical system


The control of the hydraulic station is described in the following.

9.2.1 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 343-5 For external communication

3 5 Asi-card CP 342-2 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.

9.2 Controller

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Electrical system


9.2.2 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.

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Electrical system


Example SPC200 setup

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Electrical system


The wiring within the station and the wiring to the other stations are explained in the following.

9.3.1 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 488 24 pins

Inputs 8

Outputs 8

Current consumption Max. 1A/PIN

Power supply 24 VDC

9.3 Wiring

Electrical system


123456789101112

222324

131415161718192021

OUT BIT 0OUT BIT 1OUT BIT 2OUT BIT 3OUT BIT 4OUT BIT 5OUT BIT 6OUT BIT 7POWER 24 VDCPOWER 24 VDCPOWER 0 VDCPOWER 0 VDC

IN BIT 0IN BIT 1IN BIT 2IN BIT 3IN BIT 4IN BIT 5IN BIT 6IN BIT 7POWER 24 VDCPOWER 24 VDCPOWER 0 VDCPOWER 0 VDC

syslink pin assignment01 Bit 0 Output word white02 Bit 1 Output word brown03 Bit 2 Output word green04 Bit 3 Output word yellow05 Bit 4 Output word grey06 Bit 5 Output word pink07 Bit 6 Output word blue08 Bit 7 Output word red09 24 V Power supply black1011 0 V Power supply pink-brown12 0 V Power supply purple

13 Bit 0 Input word grey-pink14 Bit 1 Input word red-blue15 Bit 2 Input word white-green16 Bit 3 Input word brown-green17 Bit 4 Input word white-yellow18 Bit 5 Input word yellow-brown19 Bit 6 Input word white-grey20 Bit 7 Input word grey-brown21 24 V Power supply white-pink2223 0 V Power supply white-blue24

Allocation I/O- Terminal

Clamp Bit Function Colour Clamp Bit Function Colour

01 0 Output White 13 0 Input Grey-pink

02 1 Output Brown 14 1 Input Red-blue

03 2 Output Green 15 2 Input White-green

04 3 Output Yellow 16 3 Input Brown-green

05 4 Output Grey 17 4 Input White-yellow

06 5 Output Pink 18 5 Input Yellow-brown

07 6 Output Blue 19 6 Input White-grey

08 7 Output Red 20 7 Input Grey-brown

09 24V Power supply Black 21 24V

Power

supply White-pink

10 22

11 0V Power supply Pink-brown 23 0V

Power

supply White-blue

12 0V Power supply purple 24

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