FMS 100 Manual - Marmara Üniversitesimimoza.marmara.edu.tr/~baris/dosyalar/FMS100_Robot... ·...

FMS 100

Manual

Robot assembly

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

Order-NR.:

Type: Manual FMS

Designation FMS100_Robotassembly_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_____________________________________________________ 11

3.1 General_____________________________________________________ 11

3.2 Robotassembly station ________________________________________ 12

3.3 Didactic structure ____________________________________________ 13

3.4 Scope of tasks of the stations __________________________________ 14

3.4.1 Mechanics ______________________________________________ 14

3.4.2 Pneumatics _____________________________________________ 14

3.4.3 Electrics ________________________________________________ 14

3.4.4 Informatics______________________________________________ 14

3.4.5 Bus technology __________________________________________ 14

4 General safety instructions_________________________________________ 15

4.1 Use according to regulations ___________________________________ 15

4.2 Handling the system __________________________________________ 15

4.2.1 Dangers in handling the machine ____________________________ 15

4.2.2 Safety precautions in standard operation _____________________ 15

4.2.3 Dangers due to electric current _____________________________ 16

4.2.4 Dangers due to pneumatic energy ___________________________ 16

4.2.5 Maintenance – Servicing – Malfunction removal ________________ 17

4.2.6 Organisational measures __________________________________ 17

4.3 Personnel___________________________________________________ 17

2 Contents

Contents


4.3.1 Notes on personnel _______________________________________ 17

4.3.2 Training operations _______________________________________ 17

4.3.3 Outside training operations ________________________________ 17

4.3.4 Safety symbols __________________________________________ 18

5 Commissioning __________________________________________________ 19

5.1 Transport ___________________________________________________ 19

5.2 Set up______________________________________________________ 20

5.2.1 General information ______________________________________ 20

5.2.2 Robot assembly 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


5.4.6 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 Behavior rules ___________________________________________ 31

6.1.2 Operation rules __________________________________________ 31

6.2 Process description___________________________________________ 32


6.2.2 Assembly process ________________________________________ 33

6.2.3 General information ______________________________________ 34

6.3 Order codes Robot assembly station PLC – COSIMIR CONTROL________ 35

6.4 Control strip robot assembly station _____________________________ 39

6.5 Reset mode _________________________________________________ 41

6.6 Automatic mode _____________________________________________ 41

6.6.1 Activating automatic mode and starting the process with network _ 41

6.6.2 Automatic start up________________________________________ 42

6.6.3 Automatic stop __________________________________________ 42

6.7 Teach mode _________________________________________________ 43

6.7.1 Teaching the robot _______________________________________ 43

6.8 Mitsubishi robot RV-E2 _______________________________________ 44

Contents


6.8.1 Teach box RV-E2 _________________________________________ 45

6.8.2 Set up RV-E2 ____________________________________________ 49

6.8.3 Interface RC-EA2 to robot __________________________________ 50

6.8.4 Teach position example ___________________________________ 56

6.8.5 Robot programs__________________________________________ 57

7 Technology _____________________________________________________ 59

7.1 drawings ___________________________________________________ 59

7.2 Modules in use ______________________________________________ 61

7.2.1 Pallet reception __________________________________________ 61

7.2.2 Housing lower part magazine _______________________________ 62

7.2.3 Housing upper part magazine_______________________________ 63

7.2.4 Battery magazine_________________________________________ 64

7.2.5 Assembly module ________________________________________ 65

7.3 Workpiece positions __________________________________________ 66

7.4 Technical datas ______________________________________________ 67

8 Pneumatic ______________________________________________________ 69

8.1 The valve terminal ____________________________________________ 69

8.2 Pneumatic supply ____________________________________________ 70

9 Electrical system _________________________________________________ 71

9.1 Power supply ________________________________________________ 71

9.2 Controller ___________________________________________________ 72

9.2.1 Controller design IPC______________________________________ 72

Contents


9.3 Wiring______________________________________________________ 73

9.3.1 I/O-Components _________________________________________ 73

Contents



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 assembly station is responsible for the assembly of an electronic handheld device.

Once a handheld device is to be assembled, the required palettes, containing the necessary components, is requested for placement onto the palette reception. In case of sub-process 406, the palettes with the pins and the printed circuit boards are to be placed onto the station manually. In this case, the housing parts derive from the magazines of the assembly station.

At first, a lower housing part is placed into the assembly position, then a printed circuit board is inserted into the lower part. The battery magazine isolates a battery, which is placed into the printed circuit board. The upper housing part is placed onto the lower housing part. The pins are inserted into the drill holes. The handheld device is returned to its retrieval position. Afterwards the second one is assembled, thus concluding the assembly 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. An IPC supplies the control.

The assembly station can be operated individually, in “stand alone” mode, for training purposes with robots.

The lower housing part magazine is designated for this operational mode. Here, the work-pieces can be isolated to be placed onto the palette receptions afterwards. At this point, operation and teaching of the robot can be taught.

3.2 Robotassembly 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.

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 General safety instructions

4.1 Use according to regulations

4.2 Handling the system

General safety instructions


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 Robot assembly station

The robot assembly station is set up at operating position 3. 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 transfer position at operating position 3, 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 robot assembly 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 robot assembly station

Commissioning


Commissioning of the system can ensue only, once all of the stations are connected to their definite position.

The robot assembly station has to be mounted on operating position 3 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 robot assembly station by means of a spirit-level and tighten the connector profiles afterwards. It may be possible, that the transfer position of operating position 3 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 realized.

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

12

34

5

67

89

BU

S

12

34

5

67

89

BU

SER

RR

ON

OFF

Previous station

Following station

Profibus with IPC

If the robot assembly station is to be connected to another installation, for example as described in complete process, communication takes place via the Profibus.

In this case the data cable is plugged into the CP 60 from the IPC. With the IPC there is no t-connector necessary. The CP60 card has to interfaces.

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.


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 Behavior 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

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Operation



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 assembly station has the task to press the device, for which no special components are required.

In automatic mode process 407

• An empty palette • A palette with 2 lower housing parts • A palette with 2 upper housing parts • A palette with pins • And a palette with 2 printed circuit boards are placed onto the assembly station. The components are transported to the assembly station by the transport system station to be placed afterwards onto the exactly defined palette deposit position by the robot.

Now the assembly process proceeds, as explained under the following point.

Once 2 electrical handheld devices have been assembled, the palette is placed onto the transport system, to be stored in the AS/RS station for further processing.

6.2 Process description

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Operation


6.2.2 Assembly process

Assembly process Step Designation From To

Step 1 Lower housing

part

Palette on

palette

position 3

Assembly

module

Step 2 Printed circuit

board

Palette on

palette

position 4

Lower housing

part on

assembly

module

Step 3 Battery Battery

magazine on

assembly

station

Printed circuit

board on

assembly

module

Step 4 Upper housing

part

Palette on

palette

position 5

Lower housing

part on

assembly

module

Step 5 Pins Palette on

palette

position 6

Upper housing

part on

assembly

module

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6.2.3 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 realized 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.

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Station

Ordernumber/ Orderdescription

Type /

Parameter

Nr. Description Available

1 Palette place 1 (empty palette) X

2 Palette place 2 (lower housing

part)

X

3 Palette place 3 (upper housing

part)

X

4 Palette place 4 (PIN) AUTO X

5 Palette place 5 (PCB) AUTO X

6 Palette place 6 (PIN) MAN X

7 Palette place 7 (PCB) MAN X

Parameter 1

Source position

15 Conveyor pickup/place position X

1 Palette place 1 (empty palette) X

2 Palette place 2 (lower housing

part)

X

3 Palette place 3 (upper housing

part)

X

4 Palette place 4 (PIN) AUTO X

5 Palette place 5 (PCB) AUTO X

6 Palette place 6 (PIN) MAN X

7 Palette place 7 (PCB) MAN X

Parameter 2

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 Global error robot X

15 Run-time error X

16 # 4000

Move palette from

source position to

target position

Return code

65535 Invalid input parameters x

6.3 Order codes Robot assembly station PLC – COSIMIR CONTROL

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Station

Ordernumber / Orderdescription

Type / Parameter Nr. Description Available

1 Magazine 1 (Lower part of

housing)

X

2 Magazine 1 (Upper part of

housing)

X

21 Palette 2 position 21 (lower

housing part)

X

22 Palette 2 position 22 (lower

housing part)

X

31 Palette 3 position 31 (upper

housing part)

X

32 Palette 3 position 32 (upper

housing part)

X

Parameter 1

Housing Source

position

80 Assembly position X

11 Palette 1 position 11 (finished

part)

X

12 Palette 1 position 12 (finished

part)

X

Parameter 2

Housing target

position

80 Assembly position X

Parameter 3

0 No errors X


2 No pallet at target position X

3 Target position occupied X

4 No lower housing at assembly

position

X

5 No work-piece at assembly

position

X

6 Palette 2 empty (Lower part) X

7 Palette 3 empty (Upper part) X

8 Magazine 1 empty X

9 Magazine 2 empty X


15 Run-time error X

16 # 4001

Move housing

from source

position to target

position

Return code

65535 Invalid input parameters X

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Station


Type /

Parameter


51 Palette 5 position 51 (PCB) AUTO X

52 Palette 5 position 52 (PCB) AUTO X

71 Palette 7 position 71 (PCB) MAN X

Parameter 1

PCB Source

position

72 Palette 7 position 72 (PCB) MAN X

Parameter 2

Parameter 3

0 No errors X


2 No pallet at assembly position X

3 Palette 5 empty (PCB) X

4 Palette 7 empty (PCB) X


15 Run-time error X

16 # 4002

Assemble PCB

from source

position

Return code


Station


Type / Parameter


Parameter 1

Parameter 2

Parameter 3

0 No errors X

1 No housing at assembly position X

2 Battery magazine empty X


15 Run-time error X

16 # 4003

Assemble battery

Return code


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Station


Type / Parameter Nr. Description Available

41 Palette 4 position 41 (Pin) AUTO X








61 Palette 6 position 61 (Pin) MAN X







Parameter 1

Pin Source

position


81 Assembly position 81 X



Parameter 2

Pin target

position


Parameter 3

0 No errors X


2 No housing at assembly position X

3 Palette 4 empty (Pin) X

4 Palette 6 empty (Pin) X

15 Run-time error X

16 # 4004

Assemble pins

from source

position to target

position

Return code


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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

6.4 Control strip robot assembly station

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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

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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. As the robot is to be adjusted first, it is necessary to keep its area of danger clear. Electrical current and air are to be available. 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. • Activate drive unit of the robot. • Danger of collision. The arm of the robot has to be removed from any danger area

of the surrounding modules. • 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.

6.6.1 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.

6.5 Reset mode

6.6 Automatic mode

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6.6.2 Automatic start up

• The palettes required, together with the belonging printed circuit boards, are requested to be placed onto the palette reception.

• In case of sub-process 406, the palettes with the pins (palette position 6) and the printed circuit boards (palette position 7) are to be placed manually onto the station, whereby the housing parts derive from the magazine of the robot assembly station.

• At first, a lower housing part is to be placed into the assembly position. • Now a printed circuit board is inserted into the lower part. • The battery magazine isolates a battery, which is placed into the printed circuit

board. • The upper housing part is placed onto the lower housing part. • The pins are to be inserted into the bores. • The handheld device is placed onto the empty palette provided. Afterwards the

second one is assembled. • This concludes the assembly process and the handheld devices are stored in the

AS/RS station for further use.

6.6.3 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.

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The teach-mode is responsible for storing the various positions. At the robot assembly station the robot can be taught.

Flashing of all of the 4 lamps during operation indicates a grave error, e.g. the communication with the robot does not function or the appearance of a gripper problem. In this case, the complete process is to be started anew.

6.7.1 Teaching the robot

The robot is not being taught by the control. In this case, teaching ensues by means of the teach-box, as described under next chapter.

The robot positions, which are to be taught, can be observed in the program head.

6.7 Teach mode

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The robot is responsible for the workpiece handling.

RV-E2

Performance

Inputs 8 Inputs for communication

Outputs 8 Outputs for communication

Max. reservation 1 workpiece/pallet

6.8 Mitsubishi robot RV-E2

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6.8.1 Teach box RV-E2

With the teach box the robot can be moved manually.

Teach box RV-E2

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Switch / Button Function

ENABL/DISABLE Switch on/off teach box

1. Enable on

2. Disable off

If the teach box is switched on, it is not possible to communicate with the drive

unit or external

EMG:STOP Press button for emergency stop

LCD-Display The actual program or the operational condition is shown here

TOOL Operation mode: TOOL-Jog-operation

Input of “= * /” in programming mode

JOINT Operation mode: hinge-Jog-operation

Input of “( ) ?” in programming mode

XYZ Operation mode: XYZ-Jog-operation

Input of “$ : ” in programming mode

SPD Choose Jog-speed

Input of “# % !” in programming mode

STOP Stop program and robot movement

The button has the same function as the STOP-button on the front side of the

drive unit

STEP/MOVE Change interpolation of program step

skip program step (press INP/EXE simultaneous)

+/FORWD Input “+” in programming mode

process program step by step forwards

-/BACKWD Input “-” in programming mode

process program step by step backwards

COND Execution conditions set up (Interpolation mode, speed and timer)

POS Change display execution conditions to Order/Position

ALARM Reset fault message and/or stopped program

-X/-W Hinge-Jog-Operation: Move Middle hinge (w-axle) in minus direction

(clockwise/top view)

XYZ-Jog-Operation: hand peak in –x direction in XYZ-coordination system

TOOL-Jog-Operation: hand peak in –x direction in tool-coordination system

Input “PQR” in programming mode

-Y/-S Hinge-Jog-Operation:Move shoulder hinge (s-axle) in minus direction (upwards)

XYZ-Jog-Operation: hand peak in –y direction in XYZ-coordination system

TOOL-Jog-Operation: hand peak in –y direction in tool-coordination system

(Clockwise/Top view)

Input “4” for data input and “MNO” in programming mode

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-Z/-E Hinge-Jog-Operation: Move elbow hinge (E-axle) in minus direction (upwards)

XYZ-Jog-Operation: hand peak in –z direction in XYZ-coordination system

TOOL-Jog-Operation: hand peak in –z direction in tool-coordination system

(Clockwise/Top view)

Input “3” for data input and “JKL” in programming mode

-A/-T TOOL-Jog-Operation: Move forearm turn hinge in minus direction (clockwise

/topview)

XYZ-Jog-Operation: move forearm turn hinge around x-axle in XYZ-coordination

system

Input “2” for data input and “GHI” in programming mode

-B/-P Hinge-Jog-Operation: Move inclination hand hinge in minus direction (upwards)

The hand peak of the robot is swung clockwise around the z-axle under

retention of the tool center in XYZ- and TOOL operation

Input “1” for data input and “DEF” in programming mode

Close hand 2 press HAND/ button simultaneous

-C/-R Hinge-Jog-Operation: Move hand turn hinge in minus direction (clockwise

/topview)



Input “1” for data input and “ABC” in programming mode

Close hand 1 press HAND/ button simultaneous

+X/+W Hinge-Jog-Operation: Move Middle hinge (w-axle) in plus direction (contrary

clockwise/top view)

XYZ-Jog-Operation: hand peak in +x direction in XYZ-coordination system

TOOL-Jog-Operation: hand peak in +x direction in tool-coordination system

Input “.” for data input and “`;^” in programming mode

+Y/+S Hinge-Jog-Operation: Move shoulder hinge (s-axle) in plus direction

(downwards)

XYZ-Jog-Operation: hand peak in +y direction in XYZ-coordination system

TOOL-Jog-Operation: hand peak in +y direction in tool-coordination system

(contrary clockwise/top view)

Input “9” for data input and “&<>” in programming mode

+Z/+E Hinge-Jog-Operation: Move elbow hinge (E-axle) in plus direction (downwards)

XYZ-Jog-Operation: hand peak in +z direction in XYZ-coordination system

TOOL-Jog-Operation: hand peak in +z direction in tool-coordination system

(contrary clockwise/Top view)

Input “8” for data input and “,@¥” in programming mode

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+A/+T TOOL-Jog-Operation: Move forearm turn hinge in plus direction (contrary

clockwise /topview)

TOOL/XYZ-Jog-Operation: move forearm turn hinge around x-axle in XYZ-

coordination system (contrary clockwise/topview)

Input “7” for data input and “YZ_” in programming mode

+B/+P Hinge-Jog-Operation: Move inclination hand hinge in plus direction

(downwards)

The hand peak of the robot is swung clockwise around the y-axle under


Input “6” for data input and “VXW” in programming mode

Open hand 2 press HAND/ button simultaneous

+C/+R Hinge-Jog-Operation: Move hand turn hinge in plus direction (contrary

clockwise /topview)



Input “5” for data input and “STU” in programming mode

Open hand 1 press HAND/ button simultaneous

INP/EXE Input data for execution instruction

Process program step by step (Incremental/decremental)

ADD/ Insert position data’s or execution instruction in program step

Move cursor in main menu upwards

RPL/ Change position data’s or execution instruction in program step

Move cursor in main menu downwards

DEL/ Delete position data’s or execution instruction in program step

Move cursor in main menu to the left

HAND/ Move hand

Move cursor in main menu to the right

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6.8.2 Set up RV-E2

For easier set up the following drawing is responsible. The ria box is necessary if the system is connected to a PLC.

Drive-Unit

I/O

-cab

le 5

0 pi

n

CN1

CN2Ria-Box

Programming PC

Drive-Unit

Teach box

Robot RV-E2 set up

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6.8.3 Interface RC-EA2 to robot

The interface facilitates the starting of programs in the robot (RV-E2), as well as the placing of status queries by means of 16 I/O-signals, with which the robot can be controlled from a PLC (S7). Up to 16 robot programs can be administrated.

The robot system RV-E2 contains an extensive I/O-interface. Both kinds of I/O are available, for free programming, as well as fixed functions.

For this system, in which the robot system RV-E2 communicates with the control of the robotics station, the following allocations have been defined.

• Starting the reference run of the robot • Starting one of 16 possible programs • Status query • Starting the control • Stopping the control • Resetting the control

The functions of the robot are in accordance with the program start; reset a.s.o. require configuration according to the allocation list (see manual RV-E2). 16 programs can be started (number 0-15) with this configuration, by means of the I/O-interface. The programs require to be loaded into the control of the robot in the numerical range of 0-15. Each one of the programs of the robot possesses its own position store. The programs are under no restrictions concerning the headings or endings of programs. The free programmable I/Os (see table) can be used by the operator, but are not necessary for the actual start of the program. The free programmable I/Os are used as status bits during program run. The reset program possesses no.1

Functions

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Signal from PLC

to robot PIN

Name ext. I/O

to drive unit

PIN RIA

XMA

Operand

PLC Function

Program selection

BIT 0 15 IN 0 13 A x.0

BCD-code for program

number **

Program selection

Bit 1 16 IN 1 14 A x.1


number **

Program selection

Bit 2 17 IN 2 15 A x.2


number **

Program selection

Bit 3 18 IN 3 16 A x.3


number **

Select program 24 IN 16 (PGN)* 17 A x.4

Program selection

according to BCD-code

start by positive edge

Start robot 25 IN 17 (Start

input) 18 A x.5

Program START (positive

signal)

Stop robot 49 IN 18 (Stop

Input) 19 A x.6

Program STOP (positive

signal)

Reset robot 50 IN 19 (Reset

Input) 20 A x.7

Program RESET (positive

signal)

* The functions given in brackets require to be adjusted by means of the respective robot configuration (see manual RV-E2).

** These 4 bit can also be used as freely programmable inputs during program flow, but this depends on application.

Allocation interface

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Signal from PLC

to robot PIN

Name ext. I/O

to drive unit

PIN RIA

XMA

Operand

PLC Function

Status BIT 0 4 OUT 0 1 E x.0 Free programmable

output*

Status Bit 1 5 OUT 1 2 E x.1 Free programmable

output*


output*


output*

Strobe 35 OUT 12 5 E x.4

Free programmable

output / standard use

STROBE*

Robot RUN 36 OUT 13 (RUN) 6 E x.4 High, during program run

Robot WAIT 37 OUT 14 (WAIT) 7 E x.5 High, when ready for new

start

Robot ERROR 38 OUT 15 (ERR) 8 E x.6 High, in case of error

* Is being used for messages from the robot to the PLC during program run.

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To move the robot, the following points have to be done.

1. Connect power supply Drive unit / 230 V 2. Connect robot cables CN1 and CN2 from Drive unit to robot. 3. Plug teach box to Drive unit. 4. Emergency strap at back side of the Drive unit or emergency circuit to ria box. 5. Unlock Emergency stop at Drive unit and teach box. 6. Switch ENABLE/DISABLE at teach box to enable. 7. Switch on Drive unit / takes some time 8. Wait till display at teach box is ready 9. First it is necessary to activate the servos. 10. Press -A button to choose run mode. 11. Press button –B to choose servo. 12. Servos are off 13. Press -B button to switch on servos - activate with INP/EXE button

Press -C button to switch off servos – activate with INP/EXE button 14. If servos are activated, switch off teach box with ENABLE/DISABLE 15. Switch on teach box with ENABLE/DISABLE again. 16. Choose TEACH mode. 17. Now it is possible to move the robot manually. 18. Press STEP/MOVE button and the axle you want.

The following three modes are available for to move the robot manually.

• Joint mode every axle separate. • XYZ mode Coordination point in the robots body or tool. • Tool mode Coordination point in the robots gripper. Here it is possible to make a

tool length correction. The modes are indicated in the teach box display. Choose one, the allocation off the buttons is shown in the following drawings.

To change the speed of the robot press

• STEP/MOVE and SPD button simultaneous

The speed is allocated in the teach box display in the right top corner. Two different speeds (slow/fast) are available.

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B-/P-

B+/P+

X-/W-

X+/W+

A+/T+

A-/T-

C+/R+

C-/R-

Joint-Mode

Y+/S+

Y-/S-

Z+/E+

Z-/E-

Functions of teach box in Joint mode

B-/P-

B+/P+

X-

X+

C-/R- C+/R+

A-/T-

A+/T-

XYZ-Mode

Y+

Y-

Z+

Z-

X+

Y+

Z+

Functions of teach box in XYZ-Mode

Operation


B-/P-

B+/P+

Z-

A-/T- A+/T+

C+/R+

C-/R-

Tool-Mode

Y-

X+

Z+

Y+

X+

Without tool length correction

With tool length correction

X+/W-

X+/W+

Y-/S-

Y+/S+

Z+/E+

Z-/E-

Functions of teach box in Tool-Mode

Operation


6.8.4 Teach position example

To re-teach a position, the following points have to be done.

1. Connect power supply Drive unit / 230 V 2. Connect robot cables CN1 and CN2 from Drive unit to robot. 3. Connect PC with cosimir industrial / educational with Drive unit. 4. Plug teach box to Drive unit. 5. Emergency strap at back side of the Drive unit or emergency circuit to ria box. 6. Unlock Emergency stop at Drive unit and teach box. 7. Switch ENABLE/DISABLE at teach box to enable. 8. Switch on Drive unit / takes some time 9. Wait till display at teach pendant is ready 10. Menu at teach box available 11. Positions have to be available in Drive unit. 12. Choose teach mode 13. Select program number (Example button –A/-T for Program 2) 14. Press INP/EXE to activate program 15. Display looks like following

PR:1 ST:1 LN:10 (No data if no program is available)

16. To change a position, press POS and ADD button simultaneous. 17. Display looks like following

MO.POS (101) Example pos. number 101 18. Choose position with +/FORWARD and -/BACKWRD or with buttons (Example –

A/-T for pos.2) 19. Select speed fast or low with 20. STEP/MOVE and SPD 21. Press INP/EXE and STEP/MOVE simultaneous, robot moves to the chosen

position 22. Now the robot moves to the new position. Movement description see chapter

(to operate the robot) Example with XYZ mode. 23. To move the robot now, press the STEP/MOVE buttons and simultaneous press

the button for the chosen axis. 24. To store the position, press STEP/MOVE and ADD simultaneously 25. Release ADD if you are sure that you want to overwrite the position. 26. Press ADD again, and the new position is stored. 27. Don’t forget to load the position list into the PC.

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6.8.5 Robot programs

• Program number 1 Initialise robot • Program number 2 Pick up pin gripper • Program number 3 Release pin gripper • Program number 5 Move palette from source position to target position • Program number 6 Move housing from source position to target position • Program number 7 Assembly PCB from source position • Program number 8 Assembly battery from magazine • Program number 9 Assembly pin from source position palette 4 to target

position • Program number 10 Assembly pin from source position palette 4 to target

position

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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 robot assembly station

7 Technology

7.1 drawings

Technology


Module positions robot assembly station

Technology


The robot assembly station is made up of a number of different function modules.

• Pallet reception • Magazine for lower housing part (magazine 1) • Magazine for upper housing part (magazine 2) • Magazine for batteries (magazine 3) • Assembly module • Robot RV-E2 (See chapter before)

7.2.1 Pallet reception

With this module it’s possible to pick up 1 palette with different workpieces.

Pallet reception

Performance

Inputs /

Outputs /

Max. reservation 1 palette

7.2 Modules in use

Technology


7.2.2 Housing lower part magazine

With this module it’s possible to distribute the housing lower part.

Housing lower part magazine

Performance

Inputs 2

Outputs 3

Max. reservation 11 Housing lower parts

Technology


7.2.3 Housing upper part magazine

With this module it’s possible to distribute the housing upper part.

Housing upper part magazine

Performance

Inputs 2

Outputs 3

Max. reservation 11 Housing upper parts

Technology


7.2.4 Battery magazine

With this module it’s possible to distribute the batteries.

Battery magazine

Performance

Inputs 2

Outputs 3

Max. reservation 12 batteries

Technology


7.2.5 Assembly module

With this module it’s possible to assemble the hendheld.

Assembly module

Performance

Inputs

Outputs 0

Max. reservation 1 hendheld

Technology


Position arrangement

7.3 Workpiece positions

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. 1700 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 robot assembly station is described in the following.

9.2.1 Controller design IPC

No. Switch position Modul Name Comment

1 - Power supply PS 10

2 Reserve

3 - Controller HC 16

4 4 Profibus card CP 60 For external communication

5 1 I/O-card OM 21 For operation

6 2 I/O-card OM 21 For robot communication

7 3 I/O-card OM 21 For vision communication

8 4 I/O-card OM 21 For modules on profile-plate

9 5 I/O-card OM 21 For modules on profile-plate

IPC controller robot assembly 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.

The IPC in the switchgear cabinet is programmed from the computer via the serial cable (RS232 cable). The serial-cable is plugged into the RS 232 interface on the programming computer and is connected directly to the IPC-Controller.

9.2 Controller

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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