Fms200

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TECHNICAL DESCRIPTION

FMS-200

FLEXIBLE AUTOMATED CELL TRAINER

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10 REASONS FOR CHOOSING THE FMS-200 SYSTEM

1. The FMS-200 is manufactured entirely from industrial grade materials of maximum strength and quality.

2. It complies with European safety directives in respect of both low voltage and

machine safety.

3. It includes a 4-metre line transfer system which integrates the various stations.

4. The process stations or layouts can work independently or integrated in the transfer in cell mode, and can change position within the transfer.

5. The automatons needed for system control are included, with mains supply

connection, and users may design their own electrical control gear based on other, different, PLCs.

6. Each of the stations incorporates a key-protected Fault Generation System which

makes it possible to work on diagnostic and repair capabilities, using the “Switches” methodology and “Virtual Repair”.

7. The FMS-200 cell has been designed for assembly of a turning mechanism with a

total of 24 variants.

8. The pallets and transfer incorporate a magnetic coding system using inductive detectors, which allow the Control System to identify the position of each pallet at any time.

9. The Practical Activities drawn up from the modular concept of the system allow the

development of skills such as: ANALYSIS, INSTALLATION /ASSEMBLY/IMPLEMENTATION, MAINTENANCE / DIAGNOSIS /FAULT REPAIR, START-UP/SET-UP, DESIGN/LAYOUT, PROGRAMMING, PREPARATION OF DOCUMENTATION, DEFINITION OF PROCEDURES, MEASURING, ETC., integrating different technologies including: Pneumatics/Electro-pneumatics, Hydraulics, Electrical Actuators, Robotics/Manipulation, Industrial Communications, Control Systems, Electric Automatisms, Safety Devices, Basic Mechanical Systems, and so on.

10. It has been conceived and designed using the pooled knowledge of two leading

companies: SMC (world leader in pneumatics and electro-pneumatics) and ALECOP (leader in the world of training).

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INDEX 1. TECHNICAL AND FUNCTIONAL DESCRIPTION……………………..……………..1

1.1 Programmable automaton with network communications system…………………..…3 1.2 Automaton programming software…………………………………………………….3

2. PROCESS STATIONS………………………………………………………….………...4 2.1 Body feed- positioning…………………………………………………………………….4

2.1.1. Station function……………………………………………………………………..4 2.1.2. Integral parts………………………………………………………………………..4 2.1.3. Technical data………………………………………………………………………5

2.2. BEARING HANDLING-FITTING LAYOUT…………………………………………..7

2.2.1. Station function……………………………………………………………………..7

2.2.2. Integral parts………………………………………………………………………..7

2.2.3. Technical data………………………………………………………………………9

2.3. HYDRAULIC BEARING PRESSING LAYOUT……………………………………...11

2.3.1. Station function……………………………………………………………………11

2.3.2. Integral parts……………………………………………………………………...12

2.3.3. Technical data……………………………………………………………………..13

2.4. SHAFT HANDLING-FITTING-MEASUREMENT-SELECTION……………………15


2.4.2. Integral parts………………………………………………………………………15

2.4.3. Technical data……………………………………………………………………..18 2.5. COVER HANDLING-FITTING-SELECTION LAYOUT………………………….…21

2.5.1. Station function…………………………………………………………………...21

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2.5.2. Integral parts………………………………………………………………………21 2.5.3. Technical data……………………………………………………………………..24

2.6. SCREW HANDLING-FITTING…………………………………………………….….27


2.6.2. Integral parts……………………………………………………………………...28

2.6.3. Technical data…………………………………………………………………….29

2.7. ROBOT SCREWDRIVER……………………………………………………………..31


2.7.2. Integral parts………………………………………………………………………31 2.7.3. Technical data……………………………………………………………………..32

2.8. UNLOADING-STORAGE-PALLETIZATION OF COMPLETED ASSEMBLY….…33

2.8.1. Station function……….……………………………………………..………….…33

2.8.2. Integral parts………….…………………………………………….….………….33

2.8.3. Technical data…………………………………………………...…..……………35

3. 4-METRE TRANSFER LINE WITH AUTOMATON AND PALLET ASSEMBLY.…..37 3.1. Transfer function and composition…………………………………..…………...……..37

3.2. Technical details of transfer………………………….…….…….…..…………….……38

4. INSTALLATION AND START- UP…………………………………………………….40

4.1. Prerequisites………………………………………………………………………….40

4.1.1. Spatial requirements …………………………………………………………40

4.1.2. Electrical requirements ………………………………………………………41

4.1.3. Air requirements ……………………………………………………………..41

4.2. Handling and packaging ……………………………………………………………..43

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4.3. Installation …………………………………………………………………………...44

4.3.1. Individual station …………………………………………………………….44

4.3.2. Cell …………………………………………………………………………..45

4.4. Start- Up ……………………………………………………………………………..46

4.4.1. Individual Station ……………………………………………………………46

4.4.2. Cell …………………………………………………………………………..48

4.5. PROCEDURE FOR USE ……………………………………………………………49

4.5.1. Individual Station ……………………………………………………………49

4.5.2. Cell …………………………………………………………………………..50

5. LOCATING AND CORRECTING FAULTS ………………………………………51

6. MAINTENANCE AND INSPECTION …………………………………………….67

6.1. Introduction ………………………………………………………………………….67

6.2. Inspection points …………………………………………………………………….67

6.2.1. Daily inspection ……………………………………………………………...67

6.2.2. Periodic inspection …………………………………………………………..67

6.3. Maintenance procedures ……………………………………………………………..68

6.3.1. Pneumatic components ………………………………………………………68

6.3.2. Electrical shafts ……………………………………………………………...68

6.3.3. Cleaning ……………...……………………………………………………...68

7. SAFETY ……………………………………………………………………………..69

7.1. General safety precautions …………………………………………………………..69

7.2. Protection and safety devices ………………………………………………………..69

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8. FAULT SIMULATION SYSTEM………………………………………………………..70

9. SETS OF PARTS FOR ASSEMBLY………………………………………………...…..71

10. EC SELF- CERTIFICATION……………………………………………………….…..72

11. SUPPORT MATERIAL………………………………………………………………....73

ANNEX A: FAULT GENERATION

ANNEX B: ELECTRIC DIAGRAMS ANNEX C: PNEUMATIC DIAGRAMS ANNEX D: GRAFCET AND CONTROL PROGRAMS ANNEX E: MECHANICAL DIAGRAMS

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1.- TECHNICAL AND FUNCTIONAL DESCRIPTION

From SMC, a world leader in Pneumatics, we introduce SMC International Training. Our clear and wholehearted international vocation defines the objectives of this company: the conception and marketing of training systems in the automation field to satisfy the training needs of educative centres and companies all over the world. An example of a Comprehensive Training System developed within the framework of this project, constitutes the Flexible Assembly System FMS-200.

Figure 1: Flexible Automated Cell Trainer FMS-200

The flexible automation cell has been specially conceived for persons to acquire professional capabilities in connection with the Occupational Groupings of Electricity/Electronics and Maintenance, such as:

- Installation, Electromechanical Maintenance and Line Transport. - Industrial Equipment Maintenance. - Automatic Control and Regulation Systems.

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It enables the development of various skills associated with pneumatic, electro-pneumatic, electrical, robotic and handling automatisms, programming and PLC technologies, industrial communications, supervision, quality control and fault diagnosis and repair. It also allows the study of a wide range of sensor types:

- Magnetic detectors. - Inductive detectors. - Hall detectors. - Photoelectric detectors. - Reed detectors. - Photochromatic detectors. - Capacitive detectors. - Linear encoders. - Etc.

The system comprises a flexible automation cell which carries out an assembly process involving a number of predetermined parts with a total of 24 different possibilities.

Figure 2: Turning mechanism Figure 3: Turning mechanism components Parts are transported between the different stations or layouts by an automated 4-metre transfer line with corresponding stoppers and precision lifters-positioners. Parts are mounted on pallets with a magnetic coding system. The process stations or layouts function either independently of the transport system, or integrated into it. The stations are situated around the transfer, and may be withdrawn for re-positioning in a different order, moved for future extensions or work in a completely independent and self-sufficient mode. Each station has its own electrical panel, where the wiring system and automaton are fully visible for study, while new elements may be fitted to the panel if desired. This electrical control panel may be made entirely independent at each station for use in programmable automaton training. In addition, students may design and build their own controls with different automatons and subsequently integrate them in the station, thereby developing a further series of skills envisaged in the Training Cycles for those persons who form the target group for the Cell.

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The front of each station incorporates the start, stop, and single and continuous cycle pushbuttons. The system is modular and may be extended, allowing future incorporation of other process stations according to user needs. The stations are mounted on aluminium sections, forming tables with a large surface area and multiple slots to allow all types of extension and modification.

The assembly process performed (turning mechanism) is as follows: Layout A: Feed body to which the other parts are assembled. Layout B: Pick and Place bearing. Layout C: Press bearing in hydraulically. Layout D: Pick and Place shaft, and verify. Layout E: Pick and Place cover. Layout F: Fit screws. Layout G: Robot screw driving. Layout H: Unloading, storage and palletization of final assembly. 1.1. PROGRAMMABLE AUTOMATON WITH NETWORK

COMMUNICATIONS SYSTEM. The standard layout includes a programmable automaton, Omron model CPM2C, panel-mounted via a DIN track. The CPM2C automaton has 6 inputs and 4 outputs, timed and programmed interrupts, internal PID, high-speed counter and 0.08us instruction time. It incorporates an RS-232 port for programming, and an DeviceNet port for communication with other automatons or PCs. The automatons which govern the cell stations communicate with each other via a network, so that each station comes ready with the necessary adapter and communications module. 1.2. AUTOMATON PROGRAMMING SOFTWARE This software enables programming of instructions and contact diagrams for all standard OMRON automatons in any desired layout. It allows ON LINE contact diagram monitoring and modification. There are options to generate listings with comments, data reports and memory listings. It incorporates help advice in all functions. The software includes an operating manual and works under the Windows environment.

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2. PROCESS STATIONS

2.1. BODY FEED-POSITIONING 2.1.1. STATION FUNCTION This first station feeds in the body which is the support for the turning mechanism, and moves it to the pallet located in the transfer system. This operation begins when the pallet is opposite the station, held in a determined location by a stop on the transfer. Confirmation that the pallet is in the correct position is provided by a microswitch which sends the appropriate signal to the automaton. 2.1.2. INTEGRAL PARTS Station A, like the others, may be divided into a series of modules. Each sub-division has been made by considering it as a set of components which performs a specific operation within the process completed at the station. Starting out from this consideration, a description is given below of the ordered sequence of actions performed for assembly of the body, indicating the components involved in each operation. - Body feed:

The feeder which supplies the body is of the gravity feed type, in that the bodies are stored in a stack so that when the bottom one is removed, the next falls into place under the effect of its own weight and that of the ones above it. The body is extracted by a pneumatic cylinder which pushes against a pusher shaped to match the profile of the body. Figure 4: Body-feed positioning

- Position verification: The body contains a housing in which the other components are fitted. This housing must always be facing upwards when the base is placed on the pallet. To check correct body orientation, a check is made by a cylinder which advances and inserts a cylindrical part in the body housing. If the body is inverted, this part cannot enter the housing, the cylinder cannot complete its stroke and the magnetic detector on the cylinder is not activated. A signal to this effect enters the PLC, resulting in an indication that the position of the body is incorrect.

- Movement to transfer point: A cylinder with a pusher at its end is used to situate the body at the point from which it is loaded onto the pallet.

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The cylinder is rectangular, to prevent the pusher from turning.

- Rejection of incorrect body: If the verification process shows the position of the body to be incorrect, a single-acting cylinder moves it towards a ramp, leaving the space clear for a new body.

- Placing body on pallet: A two-axis manipulator is used to place the body on the pallet lying on the belt conveyor. Each axis carries a parallel rod cylinder. The terminal element is a vacuum holding platform with four suction cups to absorb possible lack of alignment in height.

Figure 5: Placing body on pallet Suction is created by a vacuum ejector fitted with a vacuum switch which sends a signal to the PLC indicating that the part has been correctly clamped.

Figure 6: Vacuum Ejector

2.1.3. TECHNICAL DATA Dimensions: Table of slotted aluminium section, 900 x 540 mm. Height 900 mm. Air treatment unit: Filter to 5 µm, pressure regulator and pressure gauge. Pushbutton control: Start, stop, reset pushbuttons. Emergency button and error pilot indicator. Composition of station modules: Body feed module. Magazine capacity: 12 bodies. Actuators: - Double-acting pusher cylinder Ø16, Stroke:100mm (CD85N16-100B), with flow

regulators and initial-end position detector. Controlled by 5/2 way monostable solenoid valve.

Sensors: - Reed type magnetic detectors (D-C73L).

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Position verification module Actuators: - Double-acting cylinders Ø12, Stroke:50mm (CD85N12-50B), with flow regulators and

end position detector. Controlled by 5/2 way monostable solenoid valve. Sensors: - Reed type magnetic detector (D-A73CL)

Movement module Actuators: - Rectangular section pusher cylinder Ø25, Stroke:200mm (MDUB25-200DM), with flow

regulators and end position detector. Controlled by 5/2 way monostable solenoid valve. Sensors: - Reed type magnetic detector (D-A73CL).

Inverted body rejection module Actuators: - Single-acting ejection cylinder Ø10, Stroke:15mm (CJPB10-15H6). Controlled by 3/2

way monostable solenoid valve. Pallet insertion module Actuators: - Horizontal axis: Parallel rod cylinder Ø20, Stroke:150mm (CXSWM20-150-XB11), with

flow regulators and initial-end position detector. Controlled by 5/2 way monostable solenoid valve.

- Vertical axis: Parallel rod cylinder Ø15, Stroke:50mm (CXSM15-50), with flow regulators and initial-end position detector. Controlled by 5/2 way monostable solenoid valve.

- Holding plate: 4 telescopic suction cups Ø16 (ZPT16CNK10-B5-A10), with ejector to generate vacuum (ZU07S). Controlled by 3/2 way monostable solenoid valve.

Sensors: - Reed type magnetic detectors (D-Z73L) - Vacuum switch PNP output (PS1100-R06L)

Input/ Output Module: - DevideNet module 8 inputs/ 8 outputs Electrical control panel: - Mounted on perforated mesh 550 x 400 mm. - Accessible terminal plate with supply connections and coded I/Os. - Thermal overload switch incorporated. - I/O station: 13 inputs, 10 outputs. - Supply module: 24V/2.1A - PLC control:

- Omron model CPM2C-S110C-DRT - Digital Card 8 inputs CPM2C- 8EDC - Digital Card 8 outputs CPM2C- 8ER

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2.2. BEARING HANDLING-FITTING LAYOUT 2.2.1. STATION FUNCTION The operation carried out by the second station consists of picking the bearing and placing it inside the housing formed in the body.

Figure 7: Bearing Handling-fitting layout The task of placing the bearing is performed on the pallet brought by the belt conveyor and carrying the body located at the previous station. The bearing fitting operation requires the pallet carrying the body to be precisely situated in a predetermined place. To achieve this precision, once the pallet has been retained by a stop, it is lifted by a cylinder and centred at the same time by four pins which fit inside housings formed for this purpose in the bottom of the pallet. 2.2.2. INTEGRAL PARTS Bearing insertion requires a series of operations which are carried out by the following modules: - Bearing feed:

The bearings are held in a gravity feed magazine. This consists of a column magazine with a pusher cylinder at the bottom which extracts the bearing at the moment the cycle is to start.

Figure 8: Bearing feed

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In this case, there is a bearing proximity sensor in the form of a microswitch which allows the PLC to verify that a bearing really has been extracted following the feeding procedure. This makes it possible to determine when the bearings loaded in the feeder have run out.

Figure 9: Proximity sensor

- Transfer to measuring station: A manipulator is used to move the bearing from the feed point to the place where the following operation is to be performed. The manipulator uses a rack and pinion type rotary actuator which describes an angle of 180º. An arm is attached to the rotary actuator to move a two-finger parallel-opening gripper which grips the inner part of the bearing. This arm houses a mechanism consisting of a toothed belt and two pinions, the purpose of which is to change gripper orientation throughout the turning movement, so that when the bearing reaches the point at which it is deposited, it has no angle of inclination whatsoever.

Figure 10: Transfer to measuring station

- Height measurement:

As the station caters for the possibility of feeding bearings of differing heights, a measuring module is included to differentiate between them. The bearing is deposited on a platform, on a centring device operated by a pneumatic cylinder which locates it at a very precise initial point.

Figure 11: Height measurement

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This platform is lifted by a rodless pneumatic cylinder such that the bearing contacts with a touch trigger and gives a height reading. The touch trigger consists of a linear potentiometer with an output processed via an analogue module included in the PLC. After measurement, the lifter returns to its original position, at which time the ejector cylinder pushes the bearing towards a collection bin if it is not of the desired height.

- Bearing insertion: The final operation is performed by a manipulator comprising a rotary-linear unit with an arm to which a two-finger gripper has been fitted. After picking up the bearing, the arm is lifted, turns through 180º then drops down again to insert the bearing in the housing formed in the body.

Figure 12: Bearing insertion

2.2.3. TECHNICAL DATA Dimensions: Table of slotted aluminium section, 900 x 540 mm. Height 900 mm. Air treatment unit: Filter to 5 µm, pressure regulator and pressure gauge. Pushbutton control: Start, stop, reset pushbuttons. Emergency button and error pilot indicator. Composition of station modules: Bearing feed module Magazine capacity: 38 bearings Actuators: - Double-acting pusher cylinder Ø16, Stroke:100mm (CD85N16-100B), with flow

regulators and initial position detector. Controlled by 5/2 way monostable solenoid valve. Sensors:

- Reed type magnetic detector (D-C73L). - Proximity detector: Microswitch OMRON V-166-1C5.

Measuring station transfer module Actuators:

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- Rotary actuator: Double rack and pinion Ø50, ? max:180º ( MSQB50A), with flow regulators and 0º, 90º and 180º position detector. Controlled by 5/3 way solenoid valve, mid position closed.

- Holding arm: Two-finger parallel-opening grippers (MHK2-16D). Controlled by 5/2 way monostable solenoid valve.

Sensors: - PNP type magnetic detectors (D-A93L).

Height measuring module Actuators:

- Compact single-acting centring cylinder Ø12, Stroke:5mm (CQ2B12-5S). Controlled by 3/2 way monostable solenoid valve.

- Vertical axis: Rodless cylinder Ø16, Stroke:250mm (MY1B16G-250), with flow regulators and initial position detector. Controlled by 5/2 way bistable solenoid valve.

- Incorrect part ejection: Double-acting cylinder Ø10, Stroke:40mm (CD85N10-40), with flow regulators. Controlled by 5/2 way monostable solenoid valve.

Sensors: - Reed type magnetic detector (D-A93L). - Linear potentiometer NOVOTECHNIK TR25.

Bearing insertion module Actuators:

- Compact linear and rotary movement cylinder Ø32, Stroke:25mm (EMRQBS32-25CB), with flow regulators and initial-end of travel detection for linear movement, and 0º and 180º detection for rotary movement. Controlled by two 5/2 way monostable solenoid valves.

- Holding arm: Two-finger parallel-opening grippers (MHK2-16D). Controlled by 5/2 way monostable solenoid valve.

Sensors: - Reed type magnetic detectors (D-A73CL).

Input/ Output module: - DeviceNet module 8 inputs/ 8outputs

Electrical control panel: - Mounted on perforated mesh 550 x 400 mm. - Accessible terminal plate with supply connections and coded I/Os. - Thermal overload switch incorporated. - I/O station: 15 inputs, 13 outputs. - Supply module: 24V/2.1A. - PLC control:

- Omron Model CPM2C-S110C-DRT - Analogic Card 2 inputs/ 1 output CPM2C-MAD11. - Digital Card 16 inputs CPM2C- 16EDC - Digital Card 8 outputs CPM2C- 8ER

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2.3. HYDRAULIC BEARING PRESSING LAYOUT 2.3.1. STATION FUNCTION Following the bearing insertion operation performed by the preceding station, this third station carries out the task of pressing the bearing firmly into the body to fix it securely. In actual fact, this pressing operation is not actually carried out; instead, it is only simulated so that the finished assembly may be dismantled easily and the component parts reused. In spite of this, the components included are all industrial grade and similar to those used in numerous hydraulic applications. They allow the study of systems based on hydraulic technology which incorporate real components integrated in an authentic application. A complete hydraulic unit as required to supply the press cylinder with high pressure oil is installed under the table, avoiding the need for any additional hydraulic installation other than the electrical and pneumatic take-offs from the central transfer.

Figure 13: Hydraulic Bearing Pressing Lay-out

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2.3.2. INTEGRAL PARTS The pressing stage requires a number of operations to be performed, as detailed below.

- Insertion / extraction of assembly:

The first operation consists of moving the body with the bearing inside it from the pallet retained at the transfer to an unloading point inside the station. This handling, and the reverse process of unloading following pressing, are performed by a pneumatic rotary actuator. Figure 14: Insertion/extraction of assembly This actuator incorporates an arm with a set of four suction cups at its end, whose job is to hold the part by means of an internal vacuum generated by an ejector. To keep the body permanently horizontal throughout the turning movement, this arm incorporates a pinion and toothed belt mechanism similar to that used at the bearing insertion station.

- Feed in to press: The body to be fed in to the press is deposited on a platform fitted with two double-acting pneumatic cylinders. The first effects the transfer from the loading/unloading point to the press, while the second carries out the reverse operation following the pressing operation.

- Pressing the bearing: When the body with the bearing inside has been positioned under the hydraulic cylinder, a protective screen operated by a pneumatic cylinder drops down. This protects the user against any risk of accident, and also demonstrates a safety device widely used in this type of application. By means of a hydraulic 4/3 way directional control valve, the pressing cylinder now exerts a force which may be regulated using the pressure limiting valve incorporated in the hydraulic unit. After pressing, the cylinder returns to its original position, the screen is lifted and the assembly is pushed to the unloading position.

Figure 15: Pressing the bearing

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2.3.3. TECHNICAL DATA Dimensions: Table of slotted aluminium section, 900 x 540 mm. Height 900 mm. Air treatment unit: Filter to 5 µm, pressure regulator and pressure gauge. Pushbutton control: Start, stop, reset pushbuttons. Emergency button and error pilot indicator. Composition of station modules: Assembly insertion/extraction module Actuators: - Rotary actuator: Double rack and pinion type Ø50, ? max:180º (MSQB50A), with flow

regulators and 0º, 90º and 180º position detector. Controlled by 5/3 way solenoid valve, mid position closed.

- Holding arm: 4 Suction cups Ø16 (ZPT16UN-B5), with ejector to generate vacuum (ZU07S). Controlled by 3/2 way monostable solenoid valve.

Sensors: - PNP type magnetic detectors (D-A93L). - Vacuum switch PNP output (PS-1100-R06L).

Press feed module Actuators:

- 2 Double-acting pusher cylinders Ø12, Stroke:125mm (CD85N12-125A), with flow regulators and initial-end of stroke position detector. Controlled by 5/2 way monostable solenoid valves.


Bearing pressing module Actuators:

- Protector: Double-acting parallel rod cylinder Ø15, Stroke:100mm (CXSM15-100), with flow regulators and initial-end position detector. Controlled by 5/2 way monostable solenoid valve.

- Pressing: Compact double-acting hydraulic cylinder Ø40, Stroke:50mm (CHDQH340-50), with ATOS HQ012 flow regulators and initial-end position detector. Controlled by ATOS DHI-0714 4/3 way solenoid valve, mid position closed.

Sensors: - Reed type magnetic detector (D-Z73L and two D-A73CL).

Input/ Output module:

- DevideNet module 8 inputs/ 8 outputs.

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Electrical control panel: - Mounted on perforated mesh 550 x 400 mm. - Accessible terminal plate with supply connections and coded I/Os. - Thermal overload switch incorporated. - I/O station: 18 inputs, 11 outputs. - Supply source: 24V/2.1A. - Net filter. - Frequency converter - PLC control:

- Omron model CPM2C-S110C-DRT - Digital Card 16 inputs CPM2C- 16EDC - Digital Card 8 outputs CPM2C- 8ER - Three-phase contactor for hydraulic unit operation.

Hydraulic unit:

- Three-phase motor 380V/1.4A 0.37kW 1400rpm. - Pressure gauge. - Pressure limiter.

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2.4. SHAFT HANDLING-FITTING-MEASUREMENT-SELECTION 2.4.1. STATION FUNCTION The fourth station follows the process needed to insert a shaft into the bearing fitted at a previous station. This station represents an increase in flexibility in that it allows variety in the assemblies put together, in the form of being able to fit shafts of different materials; aluminium or nylon.

Figure 16: Shaft station The existence of these variants means that the extra operations of checking the type of material and extracting ones which are not of the desired material are added to the normal operations of feeding, handling and insertion. 2.4.2. INTEGRAL PARTS The extra operations to be carried out involve an increase in the complexity of the station, which means that its structure is noticeably different from previous stations. In this case, the components are arranged on an 8-station index plate. Successive operations are performed at these stations, a description of which is given below: - Index plate:

This element is used as a system of alternating rotary movement, in the sense that each turning movement moves the plate round by a number of degrees equal to the circumference divided by the number of defined positions. To achieve this effect, the system incorporates a pneumatic pusher cylinder with back and forth movement giving the required angular advance.

Figure 17: Index plate There are a further two stop cylinders which function alternately, one moving which holds the plate during the turn, and another fixed cylinder which locks the plate in position when movement has ceased. In this way, the plate is held firmly and the pusher cylinder can return to its initial position to await a new cycle.

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- Shaft feed: The shafts stored in a gravity type feeder are deposited on the first plate station via a step-by-step feed system involving two pneumatic cylinders. These cylinders are in a permanent counterpoise position, so that while the lower one releases the next shaft from the feeder, the upper one holds the rest in place.

FFigure 18: Shaft feed

- Shaft height measurement:

The shaft is not symmetrical and must therefore be mounted on the assembly in a particular position. The shaft is measured to check whether it has been correctly inserted. A pneumatic cylinder fitted with magnetic detector registers whether contact is made with the shaft during outstroking, or whether the cylinder is able to reach the end of its travel if the shaft is not in its proper place. Figure 19: Height measurement

- Placing shaft in correct position: If the second station on the index plate determines that the shaft has been placed upside down, a manipulator has the job of turning it round. This is achieved by holding the shaft between a two-finger gripper, lifting it by a parallel rod cylinder, then turning it over using a 180º rotary actuator and replacing it in the correct position in the housing.

Figure 20: Placing shaft in correct position

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- Shaft material detection: The next operation at this station is carried out using two consecutive index plate stations. The aim is to determine the material of which the shaft is made, it being necessary to distinguish between aluminium and nylon. This is achieved by inductive and capacitive detectors fitted to the third and fourth stations which enable the two types of materials to be differentiated.

Figure 21: Shaft material detection

- Removal of incorrect shaft: As mentioned earlier, this station fulfils the potential to work at a higher level of cell management by making a choice of shaft material to be used for the various assemblies. This means a need for some element to reject the shaft if it is not of the type indicated, an operation carried out at the fifth index plate station and involving a manipulator which removes the shaft from the plate on receiving the corresponding command. This element takes the form of a two-axis manipulator, at the extreme end of which is a suction cup to hold the top part of the shaft. Each axis comprise a parallel rod pneumatic cylinder used to lift the shaft and carry it to a removal ramp. The shaft is held by the vacuum technique consisting of a suction cup, ejector to create the necessary vacuum and a vacuum switch which sends a signal to the PLC to indicate that the shaft is securely held.

Figure 22: Removal of incorrect shaft

- Shaft insertion in assembly: Shaft insertion, carried out at the last of the index plate stations, is performed by a rotary- linear type manipulator. This rotary- linear cylinder makes it possible for a single component to pick up the shaft, take it to the unloading point and insert it. The cylinder offers the possibility of independently commanding rod instroking and outstroking as well as turns to left or right. It is this cylinder which turns an arm fitted with a suction cup used to holds the shaft throughout the movement. As in the case of the other manipulators using the vacuum technique, an ejector and vacuum switch are provided for the cylinder.

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Figure 23: Shaft insertion in assembly Given that the operation of inserting the shaft in the bearing calls for a certain precision, the pallet supporting the components and lying on the belt is, after being retained by a stop cylinder, lifted by a further cylinder which incorporates centring pins for correct positioning.

2.4.3. TECHNICAL DATA Dimensions: Table of slotted aluminium section, 900 x 540 mm. Height 900 mm. Air treatment unit: Filter to 5 µm, pressure regulator and pressure gauge. Pushbutton control: Start, stop, reset pushbuttons. Emergency button and error pilot indicator. Composition of station modules: Index plate module Actuators: - Compact double-acting pusher cylinder Ø25, Stroke:40mm (CDQ2B25-40D), with flow

regulators and initial position detector. Controlled by 5/2 way monostable solenoid valve. - Stops: 2 Compact cylinders Ø16, Stroke:10mm (CQ2B16-10D). Controlled by 5/2 way

monostable solenoid valve. Sensors: - Reed type magnetic detector (D-A73L).

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Shaft feed module Magazine capacity: 17 shafts. Actuators: - 2 Double-acting cylinders Ø10, Stroke:10mm (CD85N10-10B). Controlled by 5/2 way

monostable solenoid valve. Shaft height measuring module Actuators: - Double-acting cylinder Ø12, Stroke:50mm (CD85N12-50A), with flow regulators and

end position detector. Controlled by 5/2 way monostable solenoid valve. Sensors: - Reed type magnetic detector (D-A73CL).

Place shaft in correct position module Actuators: - Double-acting parallel opening two-finger gripper (MHK2-16D). Controlled by 5/2 way

monostable solenoid valve. - Vertical axis: Double-acting parallel rod cylinder Ø15, Stroke:50mm (CXSM15-50), with

flow regulators and initial-end position detector. Controlled by 5/2 way monostable solenoid valve.

- Rotary actuator: Double acting ? max=180º (MSUB3-180S), with flow regulators. Controlled by 5/2 way monostable solenoid valve.

Sensors: - Reed type magnetic detectors (D-Z73L).

Shaft material detection module Sensors:

- Inductive detector: OMRON E2EG-X5B1. - Capacitive detector: OMRON E2K-C25MF1.

Incorrect shaft ejection module Actuators:

- Horizontal axis: Double-acting parallel rod cylinder Ø15, Stroke:100mm (CXSM15-100), with flow regulators and initial-end position detector. Controlled by 5/2 way bistable solenoid valve.

- Vertical axis: Double-acting parallel rod cylinder Ø10, Stroke:50mm (CXSM10-50), with flow regula tors and initial-end position detector. Controlled by 5/2 way monostable solenoid valve.

- Holding arm: Suction cup Ø8 (ZPT08UN-B5), with vacuum generating ejector (ZU05S). Controlled by 3/2 way monostable solenoid valve.

Sensors: - Reed type magnetic detectors (D-Z73L). - Vacuum switch PNP output (PS-1100-R06L).

Shaft insertion in assembly module Actuators:


- Holding arm: Suction cup Ø10 (ZPT10CNK10-B5-A10), with vacuum generating ejector (ZU05S). Controlled by two 3/2 way monostable solenoid valve.

Sensors:

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- Reed type magnetic detectors (D-A73CL). - Vacuum switch PNP output (PS-1100-R06L).

Input/ Output module: - DeviceNet module 8 inputs/ 8 outputs. Electrical control panel: - Mounted on perforated mesh 550 x 400 mm. - Accessible terminal plate with supply connections and coded I/Os. - Thermal overload switch incorporated. - I/O station: 20 inputs, 16 outputs. - Supply source: 24V/2.1A. - PLC control:


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2.5. COVER HANDLING-FITTING-SELECTION LAYOUT 2.5.1. STATION FUNCTION The fourth of the components to be assembled is a cover which is fitted into a housing formed on the body for this purpose. The cover serves to retain the turning mechanism shaft mounted at the previous station. While the preceding station saw the introduction of a variant in the form of different materials for the shaft, this station increases the number of variants by offering the choice of three different materials for the cover: aluminium, white nylon and black nylon, in addition to a choice of two different cover heights, giving a total of six possible combinations for this particular assembly task. The need for appropriate checks to determine which type of cover is to be mounted at each station cycle means that this station is the most complex in terms of the operations to be carried out. It is also essential that the station control coordinates part selection operations in accordance with the commands supplied by the master responsible for production management in the FMS-200. 2.5.2. INTEGRAL PARTS The structure adopted for the cover assembly process is similar to that of the previous station. It is based on an 8-station index plate to improve the method of working at the station, as it saves space compared with other spatial arrangements of work stations, and also means that all handling operations may be carried out simultaneously to optimize the process in question.

Figure 24: Cover station The operations to be performed and the components involved are described below: - Index plate:

The 8-station index plate which moves round to effect the interchange of parts between the different stations is of similar structure to that used at the preceding station. It is operated by two cylinders, one fixed stop and one moving, together with a pusher cylinder which produces the turning movement as previously described.

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- Feed module: A gravity feeder is used to store and feed the covers. It is operated by a pusher actuated by a pneumatic cylinder and which carries out the part extraction process.

Figure 25: Feed module - Loading station:

The material feed described above supplies the covers which will later be mounted on the assembly lying ready on the pallet. First, however, the cover must be loaded on the index plate. This is performed by manipulator comprising a rotary-linear cylinder which lifts and then turns an arm fitted with a two-finger parallel opening gripper. Figure 26: Loading station The 180º turn effected by the manipulator leaves the gripper at the exact point of unloading the cover at the first index plate station.

- Material detection stations:

As described above, this station offers the possibility of working with aluminium, white nylon and black nylon respectively.

Figure 27:Inductive sensor Figure 28: Capacitive sensor Figure 29:Photoelectric cell To differentiate the first of these types, the second index plate station is fitted with an inductive pick-up which supplies a signal to the PLC only if the cover presented by the plate, as it turns, is of aluminium. Detection of the nylon covers necessitates the use of a different type of sensor, in this case capacitive, which supplies a signal when the part detected is not made of metal.

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The final cover differentiation process is that between black and white nylon, and for this purpose a photoelectric cell as in figure 31 is fitted. This component only detects white-coloured nylon covers.

- Cover measuring station:

The fact that covers of two different heights may be used necessitates a height measuring device. Owing to the teaching and training objective for which the cell has been designed, various solutions have been used to perform similar operations, so that while components such as pneumatic cylinders with correct height detectors or analogue output touch probes have been employed at other stations, this particular station uses a digital transducer which provides a pulse output, as it is a linear encoder. Figure 30: Measuring station The component used consists of a pneumatic cylinder which moves the probe until it touches the cover. An integral linear encoder in the cylinder sends pulses which are counted by a quick counter input at the PLC, making it possible to determine the distance the cylinder advances until it makes contact with the cover. This information allows direct determination of the height of the cover.

- Rejection of incorrect cover:

If the cover reaches the last-but-one index plate station, and the various material or height sensors have indicated that it is not of the material or height indicated by the central controller in charge of production, then it must be rejected. This operation is effected at this station by a two-axis manipulator, which picks the cover off the index plate and deposits it on a removal ramp if the corresponding signal is received. Figure 31: Rejection of incorrect cover The manipulator comprises two pneumatic parallel rod cylinders, at the end of which is a suction plate with three vacuum-holding cups.

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- Cover insertion: As at the previous station, the final index plate station is where the cover is fitted onto the assembly at a stop on the belt conveyor. The manipulator used for this task is of identical characteristics to the one which deposits the cover on the index plate. It has a parallel opening gripper to hold the cover, which is lifted and turned towards the unloading point by a rotary- linear pneumatic actuator.

Figure 32: Cover insertion

2.5.3. TECHNICAL DATA Dimensions: Table of slotted aluminium section, 900 x 540 mm. Height 900 mm. Air treatment unit: Filter to 5 µm, pressure regulator and pressure gauge. Pushbutton control: Start, stop, reset pushbuttons. Emergency button and error pilot indicator. Composition of station modules: Index plate module Actuators: - Compact double-acting pusher cylinder Ø25, Stroke:40mm (CDQ2B25-40D), with flow

regulators and initial position detector. Controlled by 5/2 way monostable solenoid valve. - Stops: 2 Compact cylinders Ø16, Stroke:10mm (CQ2B16-10D). Controlled by 5/2 way

monostable solenoid valve. Sensors:

- Reed type magnetic detector (D-A73CL).

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Cover feed module Magazine capacity: 19 covers. Actuators:

- Double-acting pusher cylinder Ø16, Stroke:100mm (CD85N16-100B), with flow regulators and final position detector. Controlled by 5/2 way monostable solenoid valve.

Sensors: - Reed type magnetic detector (D-C73L). - Microswitch OMRON V-166-1C5.

Loading station module Actuators:

- Compact linear and rotary movement cylinder Ø32, Stroke:25mm (EMRQBS32-25CB), with flow regulators and initial-end of travel detection fo r linear movement, and 0º and 180º detection for rotary movement. Controlled by two 5/2 way monostable solenoid valves.

- Holding arm: Two-finger parallel opening pneumatic gripper (MHKL2-16D). Controlled by 5/2 way monostable solenoid valve.


Material detection stations module Sensors:

- Inductive detector: OMRON E2EG-X5C1. - Capacitive detector: OMRON E2K-C25ME1. - Photoelectric detector: OMRON E3F2-DS30C4.

Cover measuring module Actuators:

- Double-acting cylinder with stroke reading Ø20, Stroke:50mm (CE1B20-50), with flow regulators. Controlled by 5/2 way monostable solenoid valve.

Sensors: - Linear encoder integrated in cylinder.

Incorrect cover rejection module Actuators:

- Horizontal axis: Double-acting parallel rod cylinder Ø15, Stroke:100mm (CXSM15-100), with flow regulators and initial-end position detector. Controlled by 5/2 way bistable solenoid valve.

- Vertical axis: Double-acting parallel rod cylinder Ø10, Stroke:50mm (CXSM10-50), with flow regulators and initial position detector. Controlled by 5/2 way monostable solenoid valve.

- Holding arm: 3 suction cups Ø8 (ZPT08UN-B5), with vacuum-generating ejector (ZU07S). Controlled by 3/2 way monostable solenoid valve.

Sensors: - Reed type magnetic detectors (D-Z73L). - Vacuum switch PNP output (PS-1100-R06L).

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Cover insertion module Actuators:


- Holding arm: Two-finger parallel opening gripper (MHKL2-16D). Controlled by 5/2 way monostable solenoid valve.


Input/ Output module: - DeviceNet module 8 inputs/ 8 outputs

Electrical control panel: - Mounted on perforated mesh 550 x 400 mm. - Accessible terminal plate with supply connections and coded I/Os. - Thermal overload switch incorporated. - I/O station: 24 inputs, 16 outputs. - Supply source: 24V/2.1A. - PLC control:


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2.6. SCREW HANDLING-FITTING 2.6.1. STATION FUNCTION This station carries out the final operation to fit components to the assembly under construction, and involves the insertion of four screws in four threaded holes in the base body of the turning mechanism. The technology used to effect the movements at this station, based on different pneumatic cylinders, means it is only possible to unload the screws at a single point. In consequence, an additional component is needed for the transfer to give it successive turns, so that four insertion cycles at this station will result in the four screws being fitted. The components used for this particular operation are a pneumatic lifting cylinder on which a similarly operated rotary actuator is fitted. In contrast with preceding stations, where communication between the stations and the transfer was limited to sending start messages and end of cycle indications, here there is a greater need for coordination between the units. As a result, more use is made of the possibilities offered by the automaton network for information exchange between the different stations.

Figure 33: Screw handling-fitting station

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2.6.2. INTEGRAL PARTS The screw insertion function involves a series of operations which are described below. - Screw feed:

The screws to be inserted are stored in a vertical gravity feeder, from where they are unloaded onto a housing via a step-by-step feed system involving two pneumatic cylinders working in a permanent counterpoise position, so that while the lower one instrokes to let the next screw fall from the feeder, the upper one outstrokes to hold the rest in place. Both cylinders return to their original posit ion once the screw has dropped down.

Figure 34: Screw feed - Transfer module:

The housing which receives the screws is situated on a double-acting parallel rod pneumatic cylinder whose construction allows it to be fixed by plates at each end so that it is the cylinder body which slides like a carriage. This cylinder is used to transfer the screws from point at which they are fed in to the point where the following module picks them up for fitting to the assembly.

- Screw insertion manipulator: Once the items mentioned above have deposited a screw and transferred it to the pick-up point, the pneumatic manipulator fits the screw into one of the holes in the turning mechanism body retained on the transfer. Constructed using two parallel rod cylinders, this manipulator has two degrees of freedom corresponding to the horizontal and vertical axes. Its end effector is a parallel opening two-finger gripper, used to hold the screws.

Figure 35: Screw insertion manipulator

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2.6.3. TECHNICAL DATA Dimensions: Table of slotted aluminium section, 900 x 540 mm. Height 900 mm. Air treatment unit: Filter to 5 µm, pressure regulator and pressure gauge. Pushbutton control: Start, stop, reset pushbuttons. Emergency button and error pilot indicator. Composition of station modules: Screw feed module Magazine capacity: 38 screws. Actuators: - 2 Double-acting cylinders Ø10, Stroke:10mm (CD85N10-10-B). Controlled by 5/2 way

monostable solenoid valve. Transfer module Actuators: - Double-acting parallel rod cylinder Ø20, Stroke:100mm (CXSWM20-100), with flow

regulators and initial-end position detector. Controlled by 5/2 way bistable solenoid valve.

Sensors: - Reed type magnetic detectors (D-Z73L). - Photoelectric cell OMRON E3X-A41. - Fibre optic OMRON E32-TC200. Screw insertion manipulator module Actuators:

- Horizontal axis: Double-acting parallel rod cylinder Ø25, Stroke:200mm (CXSWM25-200-XB11), with flow regulators and initial-end position detector. Controlled by 5/2 way bistable solenoid valve.

- Vertical axis: Double-acting parallel rod cylinder Ø15, Stroke:50mm (CXSM15-50), with flow regulators and initial-end position detector. Controlled by 5/2 way monostable solenoid valve.

- Holding: Two-finger parallel opening pneumatic gripper (MHK2-16D) and open-closed position detector. Controlled by 5/2 way monostable solenoid valve.

Sensors: - Reed type magnetic detectors (D-Z73L). - PNP type magnetic detectors (D-A93L).

Input/ Output module: - DeviceNet module 8 inputs/ 8 outputs.

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Electrical control panel: - Mounted on perforated mesh 550 x 400 mm. - Accessible terminal plate with supply connections and coded I/Os. - Thermal overload switch incorporated. - I/O station: 13 inputs, 9 outputs. - Supply source: 24V/2.1A. - PLC control:


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2.7. ROBOT SCREWDRIVER 2.7.1. STATION FUNCTION All the preceding stations were of a design in which actuators based on fluid technology predominated. These were primarily pneumatic components, although the study of hydraulic technology was facilitated at the bearing pressing station. With a view to matching the cell to all the most widely used techniques in industrial automation, this station introduces a new though widespread technology, that of robotics. The operation carried out by the robot consists of tightening the four screws fitted to the body of the turning mechanism at the preceding station.

Figure 36: Robot screwdriver 2.7.2. INTEGRAL PARTS Given the flexibility and numerous possibilities offered by the use of robots in automating operations, at this station it is regarded as enough to use the element for the operations needed to drive in the screws. Control of the robot’s movements between the different points it has to reach is carried out by a controller which has been specially designed for use with the particular robot used. It performs the function of controlling all the movements of all of the motors incorporated in the robot, so that the latter moves to the defined positions with great accuracy.

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It is also possible to program the robot’s movements into the controller and thereby specify what sequence of movements has to be followed for a particular process. Programming is by means of specific software to be run on PC, which communicates the transfer of information to the controller via a serial line. There is also a programming console on which it is possible to enter a series of commands, or to define the points to which the robot has to move. The positional accuracy enables the tip of the electric screwdriver to be located on each of the screws fitted in the body, before slowly screwing in the appropriate distance for the screw to be properly fixed. To avoid the possibility of uncontrolled movements during the programming phase causing any type of accident, the station is protected by screening of aluminium section with methacrylate see-through panels. This practically eliminates the risks involved in handling components of this type. 2.7.3. TECHNICAL DATA Dimensions: Table of slotted aluminium section, 900 x 540 mm. Height 900 mm. Pushbutton control: Start, stop, reset pushbuttons. Emergency button and error pilot indicator. Station elements: - MOVEMASTER EX MELFA RV-M1 MITSUBISHI 5-axis robot. Speed 2.1 m/s, 2500

storable positions, 0.02 mm accuracy, 10 speeds, 2 kg payload, 19 kg arm weight, parallel (centronics) and series (RS-232) interfaces, 16 inputs (3 switches) and 16 outputs, 1 emergency stop input.

- Electric screwdriver 3.6 V. - Methacrylate screening for user protection. Input/ Output module: - DeviceNet module 8 inputs/ 8 outputs. Electrical control panel: - Mounted on perforated mesh 550 x 400 mm. - Accessible terminal plate with supply connections and coded I/Os. - Thermal overload switch incorporated. - I/O station: 7 inputs/ 7 outputs. - Relay for screwdriver supply. - Supply source: 24V/ 0.6A. - Supply source: 5V/ 2.5A - MITSUBISHI robot driver. - MITSUBISHI robot programming console. - PLC Control:


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2.8. UNLOADING-STORAGE-PALLETIZATION OF COMPLETED ASSEMBLY 2.8.1. STATION FUNCTION One operation which is always present in flexible assembly systems, and to which all operations lead, is that of storage. Once the turning mechanism put together by the cell has been completed, at the final station it must be removed from the transport system, leaving the now empty pallet to move towards the first belt to begin work on a new assembly. This particular finished product store uses a system based on two coordinate axes, so that assemblies picked off the transporting belt may be distributed at any point on the surface of the table which constitutes the station.

Figure 37: Storage station 2.8.2. INTEGRAL PARTS As mentioned, the storage system consists of two position-controlled axes which distribute the assemblies along the surface of the table. Over these is supported a third vertical axis with which to pick up the parts.

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§ Vertical axis: The system of holding the finished assemblies incorporates four suction cups which use an ejector-produced vacuum to hold the assembly until it is positioned at its storage point. The vertical axis takes the form of a parallel rod cylinder on which the suction cups are fitted.

Figure 38: Vertical axis Figure 39: Pressure sensor As at all the stations which make use of vacuum components, a pressure-sensing element cons isting of a vacuum switch is fitted. This supplies a digital signal indicating that the ejector has produced the level of vacuum needed to hold the assembly firmly enough to ensure that it will not drop off when moved by the other axes. In this case, however, a digital vacuum switch has been incorporated which provides additional features such as displaying the instantaneous value of pressure and vacuum, and the possibility of greater accuracy than conventional units when programming the pressure value at which the output signal is generated.

§ Positioning axes: The first task in storing the finished assemblies is to situate the vertical axis mentioned above over a fixed pick-up point over the place where the pallet is retained facing the station. The finished assembly is then picked and lifted by the pneumatic cylinder forming the vertical axis. The assemblies to be stored must now be positioned at various points over the surface of the station table before being unloaded at these points. The assemblies are moved and their position controlled by two linear motorized axes, each of which consists of a motor-driven leadscrew-nut which translates the rotary motion of the motor into linear displacement of the axis carriage. The vertical pneumatic axis is attached to the first of these axes, this whole assembly being mounted on the other motorized linear axis. The result is a three-axis system, two of them being capable of positioning. From the mechanical point of view, these components incorporate a precision leadscrew with a recirculating ball system, together with two lateral linear guides of high rigidity and precision, able to withstand the forces arising out of the loads acting on the carriage.

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Axis movement and movement regulation is effected by alternating current servomotors, with an absolute encoder to provide instantaneous reading of motor rotation. Control is via two drivers which set up a closed loop position regulation system. This involves encoder feedback and the position setpoint required at any particular moment supplied by the automaton governing the station. These components allow the study of electric motors used in applications which call for position control, increasing further the number of technologies associated with automation which are dealt with by this flexible cell.

2.8.3. TECHNICAL DATA Dimensions: Table of slotted aluminium section, 900 x 650 mm. Height 990 mm. Methacrylate screening for user protection. Air treatment unit: Filter to 5 µm, pressure regulator and pressure gauge. Pushbutton control: Start, stop, reset pushbuttons. Emergency button and error pilot indicator. Composition of station modules: Vertical axis module Actuators:

- Double-acting parallel rod cylinder Ø20, Stroke:75mm (CXSWM20-75), with flow regulators and initial-end position detector. Controlled by 5/2 way monostable solenoid valve.

- Holding: 4 suction cups Ø16 (ZPT16CNK10-B5-A10), with vacuum generating ejector (ZH10BS-06-06). Controlled by 3/2 way monostable solenoid valve.

Sensors: - Reed type magnetic detectors (D-Z73L). - Digital vacuum switch PNP output (ZSE4B-01-65).

Positioning axes module Actuators:

- Linear actuators (LJ1H20Y20SC-500-F-X1). - Linear actuators (LJ1H10Y10SC-500-F-X1). - Motors OMRON R88M-UE10030VS1 and R88M-U05030VAS1

Sensors:

- Reed type magnetic detectors (D-Z73L). Input/ Output module:

- DeviceNet module 8 inputs/ 8 outputs.

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Electrical control panel: - Mounted on perforated mesh 550 x 400 mm. - Accessible terminal plate with supply connections and coded I/Os. - Thermal overload switch incorporated. - I/O station: 15 inputs, 7 outputs. - Linear actuator drivers R88D-UEP04V y R88D-UEP03V Omron. - Driver programation console R88A-PRO3U Omron.. - PLC control (Omron):

- CPU Module: CQM1H-CPU51-NL. - 16 input module CQM1-OC222 - Supply module CQM1-PA216 - Pulse generating card CQM1H-PLB21. - DeviceNet slave Card for automaton network connection CQM1-DRT21.

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3. 4-METRE TRANSFER LINE WITH AUTOMATON AND PALLET ASSEMBLY 3.1.TRANSFER FUNCTION AND COMPOSITION. The transport system is a line 4 metres long which links the layouts to facilitate the envisaged assembly process. The various layouts are linked up with the line by a quick assembly mechanical system. The transfer follows a rectangular path, and is fitted with a control cabinet with integrated automaton to organise and control the whole production sequence. This master automaton controls the rest of the automatons connected into the RS-485 network.

Figure 40: Transfer There is a longitudinal channel in the central area of the transfer to facilitate electrical connections, air supply and connection between the transfer and the various handling stations. The transfer incorporates a pallet assembly to transport parts and assemblies between the handling stations. A safety button is fitted to the transfer to stop the whole system in case of emergency. The central panel includes the master automaton which controls the entire process.

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Figure 41: Transport system All the transport system actuators, stoppers, lifters, positioners and pallet transfers are operated by a system of solenoid valves connected to the central station. Pneumatically-operated pushers unload the pallets from one section to another. The stations are assembled using screwed joints incorporated for this purpose on both station and transfer, enabling quick and precise assembly. In front of the station, there is a mechanical stop to stop the pallets, an identification code reading system and, depending on the particular process, a further series of elements for lifting, centring, turning, etc. Both the pallet retention point and the relative position of the station may be varied, making it simple to modify the distribution of the component bases of the cell. 3.2. TECHNICAL DETAILS OF TRANSFER Dimensions: 2 sections 3900 x 130 mm. Height 970 mm. Air treatment unit: Filter to 5 µm, pressure regulator and pressure gauge with incorporated pressure switch. Drive: 2 Three-phase motors 230V/1.8A 0.37kW.

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Composition: Actuators:

- 8 Compact double-acting cylinders Ø32, Stroke:25mm (ECQ2B32-25D-XSE040). Controlled by 5/2 way monostable solenoid valves.

- 3 Compact double-acting cylinders with guide Ø16, Stroke:30mm (EMGQM16-30), with flow regulators and initial-end position detector. Controlled by 5/2 way monostable solenoid valves.

- Two-direction rotary actuator αmax:90º (MSUB3-90S), with flow regulators. Controlled by 5/2 way monostable solenoid valve.

- 2 Rodless double-acting cylinders Ø20, Stroke:200mm (MY1B20G-200), with flow regulators and initial-end position detector. Controlled by 5/2 way bistable solenoid valves.

Sensors:

- Magnetic reed type detectors (D-Z73L and D-A93L). - 24 capacitive detectors OMRON E2EG-X5MC1-M1. - 2 capacitive detectors OMRON E2K-X8ME1. - 8 microswitches OMRON V-166-1C5.

Electrical control panel: - Cabinet-mounted 700 x 500mm. Depth 230mm. - Accessible terminal plate with supply connections and coded I/Os. - Thermal overload switch incorporated. - I/O station: 5 inputs, 6 outputs. - DeviceNet inputs supply source. - DeviceNet outputs supply source. - Start, stop, reset pushbuttons. 2 emergency buttons, and error indicator pilot, on line

and emergency. - 2 Three-phase motor supply contactors. - Net filter. - Frequency converter. - PLC control (Omron):

- CPU CS1G-CPU42-EV1 - Digital inputs module (16) C200H-ID212. - Digital outputs module (16) C200H-OC226-NNL. - Supply source C200HW-PA204-JPN. - DeviceNet Master Card CS1W-DRM21.

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4. INSTALLATION AND START-UP

4.1 PREREQUISITES

4.1.1 SPATIAL REQUIREMENTS The FMS200 cell is designed for working with a maximum of eight stations plus the transfer unit. In figure 44 we are shown the dimensions of the complete cell and the working space necessary in order to be able to use it. In addition, the figure provides us with the dimensions of each station for cases where a different configuration is used.

Figure 42

To get the best performance from the system, the following recommendations should be followed: - The floor should be level and have no ridging. - In the vicinity there must be no heavy machinery producing noise or vibration. - The working environment must be dust free, with no splashing of liquids. - Humidity normal with no condensation. - As far as is possible, keep EMI (Electromagnetic Incompatibility) sources at a

distance. - Check out the quality of the earth connection. - Atmospheric temperature must be moderate and extremes of temperature avoided.

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4.1.2 ELECTRICAL REQUIREMENTS FMS200 electrical supply must be in line with these requirements: - Full cell voltage: 220 V. - Minimum power necessary:

Station 1, 2 , 4 , 5 y 6 = 71 VA Station 3 = 633 VA Station 7 = 67 VA Station 8 = 671 VA Transfer = 1082 VA Complete cell total = 2810 VA

4.1.3 AIR REQUIREMENTS Details are given below of the air requirements for each station and for the whole cell: Station 1:

Element Cycles Diameter Stroke Consum.l/cycle CD85N16-100B 2 16 100 0.16 CD85N12-50B 2 12 50 0.0144 MDUB25-200DM 2 25 200 0.7852 CJPB10-15H6 1 10 15 0.0044 CXSWM20-150-XB11 2 20 150 0.3768 CXSM15-50 4 15 50 0.1412 ZU07S 19 l/min CYCLE TIME 10 sec STATION 1 TOTAL 28.l/min

Station 2:

Element Cycles Diameter Stroke Consum.l/cycle CD85N16-100B 2 16 100 0.16 MSQB50A 2 - - 0.32 MHK2-16D 4 16 10 0.056 CQ2B12-5S 1 12 5 0.0022 MY1B16G-250 2 16 250 0.4018 CD85N10-40 2 10 40 0.0125 EMRQBS32-25CB 4 32 25 0.3214 2 - - 0.084 CYCLE TIME 20 sec STATION 2 TOTAL 4.1 l/min

Station 3:

Element Cycles Diameter Stroke Consum.l/cycle MSQB50A 2 - - 0.32 CD85N12-125A 4 12 125 0.226 CXSM15-100 2 15 100 0.1413 ZU07S 19 l/min CYCLE TIME 22 sec STATION 3 TOTAL 20.8 l/min

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Station 4:

Element Cycles Diameter Stroke Consum.l/cycle CDQ2B25-40D 16 25 40 1.256 CQ2B16-10D 32 16 10 0.2572 CD85N10-10B 4 10 10 0.0125 CD85N12-50A 2 12 50 0.0452 MHK2-16D 2 16 10 0.028 CXSM15-50 2 15 50 0.0706 MSUB3-180S 2 - - 0.0248 CXSM15-100 2 15 100 0.1413 CXSM10-50 4 10 50 0.0628 EMRQBS32-25CB 4 32 25 0.3214 2 - - 0.084 ZU05S 19 l/min CYCLE TIME 4 sec STATION 4 TOTAL 53.5 l/min

Station 5:

Element Cycles Diameter Stroke Consum.l/cycle CDQ2B25-40D 16 25 40 1.256 CQ2B16-10D 32 16 10 0.2572 CD85N16-100B 2 16 100 0.1607 EMRQBS32-25CB 8 32 25 0.6428 4 - - 0.168 MHK2-16D 4 16 10 0.056 CE1B20-50 2 20 50 0.1256 CXSM15-100 2 15 100 0.1413 CXSM10-50 4 10 50 0.0628 ZU07S 19 l/min CYCLE TIME 6 sec STATION 5 TOTAL 47.7 l/min

Station 6:

Element Cycles Diameter Stroke Consum.l/cycle CD85N10-10B 4 10 10 0.0125 CXSWM20-100 2 20 100 0.2512 CXSWM25-200-XB11 2 25 200 0.785 CXSM15-50 4 15 50 0.1413 MHK2-16D 2 16 10 0.028 CYCLE TIME 30 sec STATION 6 TOTAL 2.4 l/min

Station 8:

Element Cycles Diameter Stroke Consum.l/cycle CXSWM20-75 4 20 75 0.3768 ZH10BS-06-06 34 l/min CYCLE TIME 17 sec STATION 8 TOTAL 35.3 l/min

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Transfer:

Element Cycles Diameter Stroke Consum.l/cycle ECQ2B32-25D-XSE040 16 32 25 1.2861 EMGQM16-30 6 16 30 0.1447 MSUB3-90S 4 - - 0.0496 MY1B20G-200 4 20 200 1.005 CYCLE TIME 40 sec TRANSFER TOTAL 3.7 l/min COMPLETE CELL = 28 + 4.1 + 20.8 + 53.5 + 47.7 + 2.4 + 35.3 + 3.7 = 195.5 l/min

Considering that 100 l/min is equivalent to 1CV, a 1.95 CV or 1.43 kW (which is the same) compressor is required.

4.2 HANDLING AND PACKAGING The packaging is designed to protect the modules from physical, chemical or mechanical attack that might be produced during handling and transportation.

For transoceanic transportation, the packaging is treated with waterproofing and dehydrating elements so as to provide protection against the effects of steam, salt spray, dust and other external agents that might damage module components. Details are given below of the packaging characteristics for each module:

Base Height Volume Station 1 1000 x 700 1450 mm 1.015 m3 Station 2 1000 x 700 1450 mm 1.015 m3 Station 3 1000 x 700 1450 mm 1.015 m3 Station 4 1000 x 700 1870 mm 1.309 m3 Station 5 1000 x 700 1450 mm 1.015 m3 Station 6 1000 x 700 2010 mm 1.407 m3 Station 7 1000 x 700 2010 mm 1.407 m3 Station 8 1000 x 700 1920 mm 1.344 m3 Transfer 4200 x 1400 1120 mm 6.586 m3

When handling, loading and unloading the packaging, it is advisable to employ appropriate equipment such as lift trucks. Once unloaded the stations can be transported by a minimum of two people, while the transfer requires a minimum of four. The boxes must be kept vertical at all times and must, under no circumstances, be piled one on top of another or have other objects placed on top.

44

When proceeding to unpacking, it is advisable to observe the following procedure: 1) In the first place, make sure there is enough room to carry out the unpacking

process. We recommend, as a minimum, that there be a free surface area more than three times the space occupied by each packaging.

2) Next, it is necessary to cut the straps that fasten the four seals at the bottom of the box. These are then raised so as to be able to lift the lid.

3) Two or more people must raise the lid that covers the station and store it where it will not get in the way of the following phases.

4) The next move is to loosen the wood pieces that secure the station to the bottom of the packaging. The best idea is to loosen only the top pieces, as the station can be extracted without freeing all the others: it can also prove useful to keep them for possible transportation in the future. In this operation suitable tools will be required for taking out the coach screws or nails that hold the wood in place.

5) When this operation is complete, the station must be transferred from the base of the packaging on to the floor of the space where the unpacking operation is taking place: at least two people are required to do this. It is advisable to check that all the components listed on the station delivery note are included.

6) The station has wheels, which means that it can be transported easily and effortlessly to the place where it will be used.

4.3 INSTALLATION

4.3.1 INDIVIDUAL STATION If there are any individual stations, they come with a tray with a pallet for placing the pieces. In order to avoid problems in the transportation process, the tray with the supporting pallet for the piece to be assembled has been placed in the position indicated in figure 45.

Figure 43

When installing the station, the tray has to be disassembled so that it can then be placed with the pallet facing upwards, as shown in figure 46.

45

Figure 44

The next step is to proceed to establish the electrical and pneumatic connections for the station. Before doing this we must make sure that the classroom meets the pneumatic and electrical requirements mentioned above.

For greater safety, it is wise to cut off voltage to the station using the isolating switch on the button pad before any electrical connection is made. This is done by connecting the station plug to the appropriate classroom socket.

In the same way, it is recommendable to carry out the pneumatic connection with the station air tap turned off. A six-diameter pipe must be connected from the classroom socket to the air treatment group intake for the station.

4.3.2 CELL As for the cell, the first step is to proceed to installing the transfer unit. This means following a similar process to that described above, as if we were dealing with an individual station. In this case the pneumatic connection will have to be performed using an eight-diameter pipe. The stations are provided with anchoring angle brackets and a supporting leg. The station must first be placed in front of the bars that project from the transfer unit in the position in which it is going to be sited. The station is then lifted and placed onto the outermost part of the bars, so that the table can be directly slid and pushed until it touches the transfer unit. The next move is to regulate the height of the table and immobilise it. This is what the angle bracket is for, with its adjustable supporting leg screwed into the bottom part of the table. This fastening must first be loosened and placed vertically, then situated again, while the support leg has to be adjusted until it achieves a horizontal position. In the case of station 8 (store), there is no need to put the station onto the bars, although its four support legs do have to be adjusted.

46

The angle bracket anchoring pieces must now be screwed down to fix the table to the transfer unit. When the assembly operations have been executed as indicated, the wiring connection can be set up. The recommendation is to perform and complete the wiring and assembly process on each single station before moving on to the next one. The transfer unit has connectors for communications, air and electricity, located on the station positions. Before establishing the wiring connection it is advisable to disconnect the transfer voltage and air (using the isolating switch on the side of the unit for the former and the air tap for the latter).

4.4 START-UP

4.4.1 INDIVIDUAL STATION

When installation is completed, we proceed to unit start-up. Shown below is the procedure for each station. It is advisable to read the entire procedure prior to carrying out these operations. General procedure (Stations 1, 2, 3, 4, 5, 6 and 8): 1. As a result of incidents during the transportation of the unit, it is always possible

that mechanical components become unbalanced. This will be detected in the first working cycle. Before starting, check that the fastening elements are properly tightened.

2. Feed the loader with the pieces that correspond to each station (1, 2, 4, 5 and 6). 3. Set the air input pressure regulator at above 3 Kg/m3. In the case of station 3

(press), the hydraulic supply regulator must also be set, in this case at 80 Kg/m3. 4. Carry out a visual inspection of the station to verify that there are no elements that

might distort the functioning of the system. With station 8 (store), it is necessary to check that the fairing protection gates are closed.

5. Ensure that the magnetic circuit breaker situated on the electrical control panel is in the "on" position.

6. Set the cycle selector switch on the button pad at step-by-step mode. 7. Move the sectionalising switch on the button pad to the "on" position. 8. Make sure that the emergency stop mushroom head on the button pad is

unblocked. 9. Press the button pad reset but ton to ensure that the process begins in start mode

conditions. Every time the process is halted, either during start-up or during a cycle, if the machine is not in start mode condition the defect pilot light on the button pad will blink.

10. In the cases of stations 4 and 5 (shafts and covers), if there is a need to perform a division plate evacuation cycle before beginning, the stop button on the control pad must be pressed for five seconds.

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11. When the start button is pressed the first step in the process will be executed.

Since we will be working in step-by-step mode, it will be necessary to press the start button each time we want to take a new step.

12. If any imbalance in the unit is detected, take appropriate corrective action and repeat the cycle until it functions correctly.

13. Once the cycle is over, set the cycle switch, situated on the button pad, in continuous mode. When the start button is pressed it will now perform uninterrupted cycles until the feeder runs out. At that point the pilot light will come on to indicate that there is no material in place on the table (1, 2, 4, 5 and 6).

14. The process can be halted at any moment by pressing the stop button or the emergency stop mushroom head. If the latter is pressed, once it has been deactivated it is necessary to return to initial mode conditions (reset button). After this we only have to press the start button.

Station 7 (robot): 1. Carry out a visual inspection of the station to check that there are no elements that

might distort the functioning of the system. 2. Make sure that the fairing protection gates are closed. 3. The robot drive switch at the back of the unit and the magnetic circuit breaker

situated on the electrical control panel must be in the "on" position. 4. Set the cycle switch on the button pad to step-by-step mode. 5. Move the load switch on the button pad to the "on" position. 6. Check that the emergency stop mushroom head on the button pad is unblocked. 7. Press the reset button on the button pad to ensure that the process begins in start

mode conditions. Each time the process is halted, either during start-up or during a cycle, if the station is not in start mode condition the defect pilot light on the button pad will start blinking. In addition the drive unit error led lights up accompanied by the sound of a buzzer.

8. When the start button is pressed the first step in the process will be executed. Since we will be working in step-by-step mode, it will be necessary to press the start button each time we wish to take a new step.

9. If any imbalance in the unit is detected, take appropriate corrective action and repeat the cycle until it functions correctly. It is quite likely that slight modifications have to be made to the robot's screwing movements so that it performs its duty correctly. To do this the robot manual must be consulted.

10. When the cycle is over, set the cycle switch on the button pad to continuous mode. When the start button is pressed it will now execute an uninterrupted cycle.

11. The process can be halted at any time by pressing the stop button or the emergency stop mushroom head. If the latter is pressed, once it has been deactivated it will be necessary to return to initial mode conditions (reset button on the button pad and drive unit). After this we only have to press the start button on the button pad.

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4.4.2 CELL In the case of the cell, before proceeding to starting up the stations it is

necessary to start the transfer unit running, since both the electrical and pneumatic feed for each station are obtained from their connection to it.

Start-up procedure

1. Due to incidents during the transportation of the unit, it is always possible that some imbalance is produced in the mechanical components. Before beginning, it is advisable to check that the holding elements are well tightened.

2. Set the air input pressure regulator at above 4 Kg/m3 : should the pressure drop below this value the defect pilot on the transfer unit will start blinking.

3. Carry out a visual inspection of the system to be certain there are no elements that might distort its functioning.

4. Check that the magnetic circuit breaker on the unit is in the "on" position. 5. Move the load switch on the side of the unit to the "on" position. The voltage

indicator pilot light in the transfer unit will light up. 6. Make sure that the emergency mushroom heads are unblocked. 7. When the start button is pressed the transfer unit will start to function. 8. Should any imbalance be detected in the unit, take the appropriate corrective

measures and repeat the cycle until it functions correctly. 9. The process can be ha lted at any time by pressing the stop button or the

emergency stop mushroom head. Afterwards we only have to press the start button for the process to be renewed.

10. Once the transfer unit is running and the stations have been correctly installed, we proceed to initiate the start-up of each station, ascertaining that each one is functioning correctly, firstly in manual and then in automatic mode.

11. Finally, the functioning of the system must be checked with all the stations in automatic mode, feeding the transfer unit with the pallets.

12. Due to reasons mentioned earlier, it is very likely that some imbalance be produced between the transfer unit and the station: to resolve this problem slight adjustments will have to be made before achieving optimum performance.

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4.5 PROCEDURE FOR USE The start-up procedure for the first cycle of functioning after installation has been described above. We now proceed to explain the process for normal use.

4.5.1 INDIVIDUAL STATION General procedure (Stations 1, 2, 3, 4, 5, 6 and 8): 1. Feed the loader with the pieces that correspond to the station (1, 2, 4, 5 and 6). 2. See that the station's air input pressure regulator is registering above 3 Kg/m3. In

the case of station 3 (press), check that the hydraulic supply regulator is indicating above 80 Kg/m3.

3. Carry out a visual inspection of the station to see that there are no elements that might distort the functioning of the system. In the case of station 8 (store) check that the fairing protection gates are closed.

4. Ensure that the magnetic circuit breaker situated on the electrical control panel is in the "on" position.

5. Set the cycle switch on the button pad to the desired mode. 6. Move the load switch on the button pad to the "on" position. 7. Make sure that the emergency stop mushroom head is unblocked. 8. Press the reset button on the button pad to ensure that the process begins in

starting mode conditions. Every time the process is halted, whether during start-up or during the cycle, if the station is not in starting mode condition the defect pilot light on the button pad will start blinking.

9. In the case of stations 4 and 5 (shafts and covers), if there is a need to perform a division plate evacuation cycle before starting, the stop button on the button pad must be pressed in for five seconds.

10. If the manual cycle has been selected, each time it is required to execute a step in the process the start button must be pressed. If automatic has been selected it is only necessary to press once.

11. If the feeder runs out, the warning pilot light will come on to indicate there is no material in position on the table (1, 2, 4, 5 and 6).

12. The process can be halted at any time by pressing the stop button or the emergency stop mushroom. If the mushroom is pressed, once it is deactivated it is necessary to return to starting mode conditions (reset button). Afterwards it will be sufficient to press the starter button.

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Station 7 (robot): 1. Carry out a visual inspection of the station to check that there are no elements that

might distort the system's performance. 2. Ensure that the fairing protection gates are closed. 3. The switch at the back of the robot drive unit and the magnetic circuit breaker on

the electrical control panel must be in the "on" position. 4. Set the cycle switch on the button pad to the desired mode. 5. Move the load switch on the button pad to the "on" position. 6. Make sure that the emergency stop mushroom head is unblocked. 7. Press the reset button on the button pad to ensure that the process will begin in

starting mode conditions. Each time the process is halted, whether during start-up or during a cycle, if the station is not in starting mode conditions the defect pilot light on the button pad will start blinking. In addition the unit's drive error led will light up, accompanied by the sound of a buzzer.

8. If the continuous cycle has been selected, when the starter button is pressed the cycle will be executed. If we are working in step-by-step mode, it will be necessary to press the starter button each time we wish to perform a new step.

9. The process can be halted at any point by pressing the button or the emergency stop mushroom. If the mushroom head is pressed, once it has been deactivated it will be necessary to return to starting mode conditions (reset buttons on the button pad and the drive unit). Afterwards it will be sufficient to press the starter button on the button pad again.

4.5.2 CELL Procedure for use

1. Carry out a visual inspection of the system to check that there are no elements that might distort its performance.

2. Check that the defect indicator pilot light is not blinking (insufficient pressure). 3. Move the load switch on the side of the unit to the "on" position. Make sure that

the voltage indicator pilot light on the transfer unit lights up. 4. Make sure that the emergency stop mushroom heads are unblocked. 5. When the starter button is pressed the transfer unit will begin to function. 6. The process can be halted at any time by pressing the stop button or the

emergency stop mushroom. Afterwards it is sufficient to press the starter button again in order for functioning to be renewed.

7. When the transfer unit is functioning, the running procedure for the stations is carried out.

8. Feed the transfer unit with empty pallets, placing them at the beginning of the cell.

9. When the units are stored in the last station, the empty pallets are re- fed, since the transfer unit constitutes a closed circuit. The stations will stop when the material from their stores finishes, this circumstance being detected by the desktop warning pilot lights which will light up to indicate this. With the cell stopped, we now move on to extract the assembled units, disassemble them and distribute them among the different stores.

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5. LOCATING AND CORRECTING FAULTS STATION 1

No. Symptom Possible cause Remedy 1.1 The station does

not start after the start button is pressed

1) The station is unplugged or the classroom is without voltage 2) The magnetic circuit breaker is open 3) The emergency stop button is locked 4) The air intake is not connected or the air valve is open 5) The line breaker is open 6) Switch inside the fault box producing the failure activated 7) Cell unplugged 8) Transfer unit magnetic circuit breaker open 9) Transfer unit emergency stop button is locked 10) Cell air supply not connected or transfer unit air valve open

1) Plug the station in or supply voltage to the classroom 2) Close the switch (ON), if it breaks again when restarted then the power installed is insufficient 3) Unlock the emergency stop button and press reset 4) Connect the air intake or close the air valve 5) Close line breaker 6) Close off the fault box switch 7) Plug cell in 8) Shut off switch (ON) on transfer unit, if it breaks again when restarted then the power supply installed is insufficient 9) Unlock emergency button 10) Connect air intake or close transfer unit air valve

1.2 Station does not start up after the start button has been pressed and the defect pilot light on the button pad is blinking

1) The station is not operating under starting mode conditions 2) The emergency stop button is locked and the station is not operating under start mode conditions

1) Press reset 2) Unlock button and press reset

1.3 The station will not start when the start button has been pressed and the desktop pilot light comes on

1) The material feeder is empty 2) The material feeder is clogged

1) Feed the station store with the appropriate pieces 2) Unclog the feeder

1.4 The station starts but after a short time it stops

1) Not enough air is reaching the actuators 2) The pneumatic installation in the classroom does not meet minimum requirements

1) Set the station air pressure at 3 Kg/m3 and the cell air regulator at 4 Kg/m3 2) Use a bigger compressor or transfer to a more suitable classroom

1.5 An actuator is

moving at excessive speed

1) The speed controllers are set at minimum

1) Regulate the flow until reaching the desired speed

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1.6 An actuator is moving far too slowly

1) The speed controllers are set at maximum 2) The station air regulation does not reach the minimum value required 3) The cylinder gaskets are worn

1) Regulate the flow until it acquires the speed desired 2) Set the station air pressure at 3 Kg/m3 3) Change gaskets or cylinder as circumstances dictate

1.7 The station always stops when it reaches the same point

1) Switch inside the fault box producing the failure activated 2) Detector faulty 3) Solenoid valve faulty

1) Shut off the switch in the fault box 2) Replace detector 3) Substitute valve

1.8 Piece to be set wrongly placed by one of the station components

1) Detector faulty 2) Holding elements loose 3) Station pieces poorly adjusted 4) Switch inside the fault box producing the failure activated

1) Replace detector 2) Tighten loose screws 3) Adjust pieces 4) Shut off switch in fault box

1.9 The vacuum pads do not have sufficient force to hold the piece

1) Vacuum ejector damaged 2) Station air regulation does not reach the minimum required

1) Substitute ejector 2) Set the station air pressure at 3 Kg/m3

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STATION 2

No. Symptom Possible cause Remedy 2.1 The station does

not start when the start button has been pressed

1) The station is unplugged or the classroom is without voltage 2) The magnetic circuit breaker is open 3) The emergency stop button is locked 4) Air intake is not connected or air valve open 5) The line breaker is open 6) Switch inside the fault box producing the failure activated 7) Cell unplugged 8) Transfer unit magnetic circuit breaker open 9) Transfer unit emergency stop button locked 10) Cell air not connected or transfer air valve open

1) Plug station in or supply classroom with voltage 2) Shut switch off (ON), if it breaks again when restarted then the power supply installed is insufficient 3) Unlock the emergency stop button and press reset 4) Connect the air intake or close air valve 5) Close line breaker 6) Shut the fault box switch off 7) Plug cell in 8) Shut off transfer unit switch (ON), if it breaks again when restarted then the power supply installed is insufficient 9) Unlock emergency stop button 10) Connect air intake or close off transfer unit air valve

2.2 The station will not start when the start button has been pressed and the defect pilot light on the button pad is blinking

1) The station is not operating under start mode conditions 2) The emergency stop button is locked and the station is not operating under start mode conditions

1) Press reset 2) Unlock emergency stop button and press reset

2.3 The station will not start when the start button has been pressed and the desktop pilot light comes on



2.4 The station starts but stops after a short while

1) Not enough air is getting to the actuators 2) The pneumatic installation in the classroom does not meet minimum requirements


2.5 An actuator is

moving excessively fast


1) Regulate the flow until reaching the speed desired

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2.6 An actuator is moving far too slow

1) The speed controllers are set at maximum 2) The station air setting does not reach the minimum value required 3) The cylinder gaskets are worn

1) Regulate the flow until reaching the speed desired 2) Set the station air pressure at 3 Kg/m3 3) Change gaskets or cylinder as circumstances dictate

2.7 The station stops whenever it reaches the same point

1) Switch inside fault box producing the failure activated 2) Detector faulty 3) Solenoid valve faulty

1) Shut off the fault box switch 2) Replace detector 3) Substitute valve


1) Detector faulty 2) Holding elements loose 3) Station pieces incorrectly adjusted 4) Switch inside fault box producing the failure activated

1) Replace detector 2) Tighten loose screws 3) Adjust pieces 4) Shut off the fault box switch

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STATION 3

No. Symptom Possible cause Remedy 3.1 The station will not

start when the start button has been pressed

1) The station is unplugged or the classroom is without voltage supply 2) The magnetic circuit breaker is open 3) The emergency stop button is locked 4) Air intake not connected or air valve is open 5) The line breaker is open 6) Switch inside fault box producing the failure activated 7) Cell unplugged 8) Transfer unit magnetic circuit breaker open 9) The emergency stop button on the transfer unit is locked 10) Cell air not connected or air valve on transfer unit open

1) Plug the station in or feed the classroom with voltage supply 2) Close the switch (ON), if it breaks again when restarted then the power installed is insufficient 3) Unlock emergency stop button and press reset 4) Connect up air intake or close air valve 5) Close line breaker 6) Shut down the fault box switch 7) Plug cell in 8) Close the transfer unit switch (ON), if it breaks again when restarted then the power installed is insufficient 9) Unlock emergency stop button 10) Connect up air intake or close off air valve on transfer unit




3.3 The station starts but stops again after a short while

1) Insufficient air is reaching the actuators 2) The pneumatic installation in the classroom does not meet minimum requirements

1) Set the station air pressure at 3 Kg/m3 and the cell air regulator at 4 Kg/m3 2) Install a bigger compressor or transfer to a more suitable classroom

3.4 An actuator is moving at excessive speed



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3.5 An actuator is

moving far too slowly

1) The speed controllers are set at maximum 2) The station air regulation does not reach the minimum value required 3) The cylinder gaskets are worn

1) Regulate the flow until reaching the desired speed 2) Set the station air pressure at 3 Kg/m3 3) Change gaskets or cylinder as circumstances dictate



1) Close off fault box switch 2) Replace detector 3) Substitute valve


1) Detector faulty 2) Holding elements loose 3) Station pieces wrongly adjusted 4) Switch inside fault box producing the failure activated

1) Replace detector 2) Tighten loose screws 3) Adjust pieces 4) Close off fault box switch


1) Vacuum ejector damaged 2) Station air regulation does not reach the minimum required


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STATION 4

No. Symptom Possible cause Remedy 4.1 The station will no t


1) The station is unplugged or the classroom is without voltage supply 2) The magnetic circuit breaker is open 3) The emergency stop button is locked 4) Air intake not connected or air valve is open 5) The line breaker is open 6) Switch inside fault box producing the failure activated 7) Cell unplugged 8) Transfer unit magnetic circuit breaker open 9) The emergency stop button on the transfer unit is locked 10) Cell air not connected or transfer unit air valve open

1) Plug station in or supply classroom with voltage 2) Close the switch (ON), if it breaks again when restarted then the power installed is insufficient 3) Unlock emergency stop button and press reset 4) Connect up air intake or close air valve 5) Switch off line breaker 6) Switch off fault box switch 7) Plug cell in 8) Turn the transfer unit switch (ON) off, if it breaks again when restarted then the power installed is insufficient 9) Unlock emergency stop button 10) Connect up air intake or close transfer unit air valve


1) The station is not operating under start mode conditions 2) The emergency stop button is locked and the station is not operating in start mode conditions


4.3 The station will not start when the start button has been pressed and the desktop defect pilot light is blinking



4.4 The station starts up but stops after a short while

1) Insufficient air reaching the actuators 2) The pneumatic installation in the classroom does not meet minimum requirements

1) Set the station air pressure at 3 Kg/m3 and the cell air regulator at 4 Kg/m3 2) Install a bigger compressor or transfer to a more suitable classroom

4.5 An actuator is



1) Regulate the flow until reaching the speed required


1) The speed controllers are set at maximum 2) The station air regulation does not reach the minimum

1) Regulate the flow until reaching the speed required 2) Set the station air pressure at 3 Kg/m3

58

value required 3) The cylinder gaskets are worn

3) Change gaskets or cylinder as circumstances dictate



1) Turn off switch in fault box 2) Replace detector 3) Substitute solenoid valve


1) Detector faulty 2) Holding elements loose 3) Station pieces wrongly adjusted 4) Switch inside the fault box producing the failure activated

1) Replace detector 2) Tighten loose screws 3) Adjust pieces 4) Turn off switch in fault box


1) Vacuum ejector damaged 2) Regulation of station air does not reach the minimum value required

1) Substitute ejector 2) Set station air pressure at 3 Kg/m3

4.10 Sometimes correct pieces are expelled

1) Capacity detector displaced 2) Switch inside the fault box producing the failure activated

1) Adjust capacity detector 2) Turn off switch in fault box

4.11 The division plate has stopped and will not move despite attempts to restart it

1) Locking cylinders seized 1) Manually activate the corresponding slenoid valve so that the cylinders return to their position

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STATION 5



1) The station is unplugged or the classroom is without voltage supply 2) Magnetic circuit breaker open 3) The emergency stop button is locked 4) Air intake not connected or air valve is open 5) The line breaker is open 6) Switch inside fault box producing the failure activated 7) Cell unplugged 8) Transfer unit magnetic circuit breaker open 9) The emergency stop button on the transfer unit is locked 10) Cell air not connected or transfer air valve open

1) Plug station in or supply voltage to classroom 2) Close the switch (ON), if it breaks again when restarted then the power installed is insufficient 3) Unlock emergency stop button and press reset 4) Connect air intake or close air valve 5) Switch off line breaker 6) Turn off switch in fault box 7) Plug cell in 8) Close the transfer unit switch (ON), if it breaks again when restarted then the power installed is insufficient 9) Unlock emergency stop button 10) Connect air intake or close transfer unit air valve


1) The station is not operating under start mode conditions 2) The emergency stop button is locked and the station is not operating in start mode conditions



1) Material feeder is empty 2) Material feeder is clogged

1) Feed the station store with the appropriate pieces 2) Unclog feeder

5.4 The station starts but stops again after a short while

1) Insufficient air reaching actuators 2) The pneumatic installation in the classroom does not meet minimum requirements


5.5 An actuator is



1) Regulate flow until reaching the desired speed


1) The speed controllers are set at maximum 2) The station air setting

1) Regulate the flow until reaching the speed desired 2) Set the station air pressure

3

60

does not reach the minimum required value 3) Cylinder gaskets are worn

at 3 Kg/m3 3) Change gaskets or cylinder as dictated by circumstances



1) Turn off switch in fault box 2) Replace detector 3) Substitute valve


1) Detector faulty 2) Holding elements loose 3) Station pieces poorly adjusted 4) Switch inside fault box producing the failure activated



1) Vacuum ejector damaged 2) Station air setting does not reach minimum value required

1) Substitute ejector 2) Set station air pressure at 3 Kg/m3

5.10 Sometimes correct pieces are expelled

1) Capacity detector displaced 2) Optical detector displaced 3) Switch inside fault box producing the failure activated

1) Adjust capacity detector 2) Adjust optical detector 3) Turn switch in fault box off

5.11 The division plate has stopped and will not move despite an attempt to restart it

1) Locking cylinders seized 1) Manually activate the corresponding solenoid valve so that the cylinders return to their position

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STATION 6



1) The station is unplugged or the classroom is without voltage supply 2) Magnetic circuit breaker open 3) The emergency stop button is locked 4) Air intake not connected or air valve open 5) Line breaker open 6) Switch inside fault box producing the failure activated 7) Cell unplugged 8) Transfer unit magnetic circuit breaker open 9) The emergency stop button on the transfer unit is locked 10) Cell air not connected or transfer air valve open

1) Plug station in or supply classroom with voltage 2) Close the switch (ON), if it breaks again when restarted then the power installed is insufficient 3) Unlock emergency stop button and press reset 4) Connect air intake or close air valve 5) Turn line breaker off 6) Turn off switch in fault box 7) Unplug cell 8) Close the transfer unit switch (ON), if it breaks again when restarted then the power installed is insufficient 9) Unlock emergency stop button 10) Connect air intake or close transfer air valve


1) The station is not operating in start mode conditions 2) The emergency stop button is locked and the station is not operating under start mode conditions





6.4 The station starts but after a short while stops again


1) Set the station air pressure at 3 Kg/m3 and the air regulator for the cell at 4 Kg/m3 2) Use a bigger compressor or transfer to a more suitable classroom

6.5 An actuator is





1) The speed controllers are set at maximum


62

2) The air station setting does not reach the minimum value required 3) The cylinder gaskets are worn

2) Set the station air pressure at 3 Kg/m3 3) Change gaskets or cylinder as circumstances require



1) Turn off switch in fault box 2) Replace detector 3) Substitute valve


1) Detector faulty 2) Holding elements loose 3) Station pieces poorly adjusted 4) Switch inside fault box producing the failure activated


63

STATION 7



1) The station is unplugged or the classroom is without voltage supply 2) Magnetic circuit breaker open 3) The emergency stop button is locked 4) Line breaker open 5) Cell unplugged 6) Transfer unit magnetic circuit breaker open 7) The emergency stop button on the transfer unit is locked 8) Cell air not connected or transfer air valve is open

1) Plug station in or supply classroom with voltage 2) Close the switch (ON), if it breaks again when restarted then the power installed is insufficient 3) Unlock emergency stop button and press reset 4) Shut down line breaker 5) Plug cell in 6) Close the transfer unit switch (ON), if it breaks again when restarted then the power installed is insufficient 7) Unlock emergency stop button 8) Connect air intake or close transfer air valve




For faults associated with the robot consult the robot manual

64

STATION 8



1) The station is unplugged or the classroom is without voltage supply 2) Magnetic circuit breaker open 3) The emergency stop button is locked 4)Air intake not connected or air valve open 5) Line breaker is open 6) Cell unplugged 7) Transfer unit magnetic circuit breaker open 8) The emergency stop button on the transfer unit is locked 9) Cell air not connected or transfer air valve open

1) Plug station in or supply classroom with voltage 2) Close the switch (ON), if it breaks again when restarted then the power installed is insufficient 3) Unlock emergency stop button and press reset 4) Connect air intake or close air valve 5) Shut line breaker down 6) Plug cell in 7) Close the transfer unit switch (ON), if it breaks again when restarted then the power installed is insufficient 8) Unlock emergency stop button 9) Connect air intake or close transfer air valve




8.3 The station starts up but after a short while it stops again






65

8.5 An actuator is

moving far too slowly

1) The speed controllers are set at maximum 2) The station air setting does not reach the minimum value required 3) Cylinder gaskets worn

1) Regulate the flow until reaching the speed desired 2) Set the station air pressure at 3 Kg/m3 3) Change gaskets or cylinder as circumstances dictate


1) Detector faulty 2) Solenoid valve faulty

1) Replace detector 2) Substitute valve


1) Detector faulty 2) Holding elements loose 3) Station pieces poorly adjusted 4) Imbalance between transfer and station

1) Replace detector 2) Tighten loose screws 3) Adjust pieces 4) Modify the corresponding co-ordinate in the PLC program


1) Vacuum ejector damaged 2) Station air setting does not reach the minimum value required


66

CELL


start when the start button has been pressed and the voltage pilot light is off

1) The cell is unplugged or the classroom is without voltage supply 2) Magnetic circuit breaker open 3) The emergency stop button is locked

1) Plug cell in or supply voltage to classroom 2) Close the switch (ON), if it breaks again when restarted then the power installed is insufficient 3) Unlock emergency stop button and press reset

9.2 The cell will not start when the start button has been pressed and the defect pilot light on the unit is blinking

1) Air intake not connected or air valve is open

1) Connect air intake or close air valve

9.3 The cell starts up but after a short while it stops again

1) Insufficient air reaching actuators 2) The pneumatic installation in the classroom does not meet minimum requirements

1) Set the cell air pressure at 4 Kg/m3 2) Use a bigger compressor or transfer to a more suitable classroom




9.5 An activator is moving far too slowly

1) The speed controllers are set at maximum 2) The cell air setting does not reach the minimum value required 3) The cylinder gaskets are worn

1) Regulate the flow until reaching the speed desired 2) Set the cell air pressure at 4 Kg/m3 3) Change gaskets or cylinder as circumstances dictate

9.6 The cell always stops when it reaches the same point

1) Detector faulty 2) Solenoid valve faulty

1) Replace detector 2) Substitute valve

9.7 The cell frequently comes to a halt but not always in the same place

1) There are more pallets than there should be in the cell (no. stations –2)

1) Remove excess pallets

67

6. MAINTENANCE AND INSPECTION

6.1. INTRODUCTION It is imperative that the procedures for maintenance and inspection outlined on

these pages be scrupulously observed in order to guarantee the best performance from the cell over a long period of time. As well as the daily inspections, periodic inspections should also be carried out.

6.2 INSPECTION POINTS

6.2.1 DAILY INSPECTION Inspection point Corrective action Be sure that there are no obstacles in the station that might distort the system's performance

Remove

Check to see that no components are loose, out-of-true or wrongly positioned

Take appropriate corrective action

Make sure sufficient air is reaching the station/transfer unit

See "Locating and Correcting Faults"

Ascertain that voltage is reaching the station/transfer unit

See "Locating and Correcting Faults"

6.2.2 PERIODIC INSPECTION Inspection point Corrective action Check that the filter condensate level does not go beyond the marks

Bleed: see maintenance procedures 6.3.1

Make sure that the filter pressure does not drop below a bar

Replace cartridge filter: see maintenance procedures 6.3.1

Look at the screws and nuts in case they are slack or have come loose (6 months)

Tighten using the appropriate tool

See that the cylinders are functioning correctly (6 months)

Change the gaskets if needs be: see maintenance procedures 6.3.1

Lubrication of station 8 shafts (6 months) Lubrication: see maintenance procedures 6.3.2

Examine the state of the shaft belts on the robot (6 months)

Change the belts: see robot manual

Check for disk brake-pad wear on the robot shafts (6 months)

Change the pads: see robot manual

Check for wear on the robot shaft servomotor brushes (6 months)

Change brushes: see robot manual

Clean cell (6 months) Clean: see maintenance procedures 6.3.4

68

Check for wear on the robot's beginning and end of travel limit switch gear (1 year)

Change gears: see robot manual

Check the robot bearings (2 years) Change bearings: see robot manual Examine the motor reduction gears on each robot shaft (2 years)

Lubricate gears: see robot manual

Check the robot to see if there are damaged cables (2 years)

Change cables: see robot manual

6.3 MAINTENANCE PROCEDURES

6.3.1 PNEUMATIC COMPONENTS - In general, the pneumatic components of the FMS200 are lubricated for life and there

is no need to carry out any maintenance of this kind on them. It is possible that, over a long period of time, the internal gaskets of the cylinders may suffer from attrition. In this eventuality, if the cylinder is detachable the gaskets have to be replaced. If it is not detachable it will have to be replaced by another cylinder.

- It is recommendable every so often to carry out periodic bleeding of the water that

accumulates in the cell's air conditioning units. The filter condensate level should never go over the maximum indicated on the filter bowl.

- If a filter pressure drop higher than a bar is detected, the cartridge filter must be

replaced with a new one.

6.3.2 ELECTRICAL SHAFTS The electrical shafts on station 8 require periodic inspection: after every six months of continuous work or after a month at standstill. This inspection must involve a check on the unit holding elements, such as screws and nuts, in case they are loose. It is also necessary to clean the feed shaft with the right kind of grease, moving the carriage backwards and forwards. The linear guide runners have to be greased as well, using an appropriate tool. Important Note: The grease used must not contain fluorine.

6.3.3 CLEANING For the periodic cleaning operations on the FMS200 a clean cloth that leaves no fibre traces can be used, whilst it is not advisable to use any cleaning product, in particular those containing alcohol, solvents or chlorinated compounds.

69

7 SAFETY

7.1 GENERAL SAFETY PRECAUTIONS - Once the process has begun, care must be taken to avoid adding pieces to, or

removing pieces from, the respective stores or pallets in circulation. - In general, the stations should not be manipulated with whilst the machine is

running. - When proceeding to the disassembly of the mechanism, do not leave any pieces

behind inside the main body. - Under no circumstances must the protection and safety devices described below be

tampered with. - If the stations have to be physically dealt with after a halt, to extract a fallen piece,

for instance, always press the emergency stop mushroom head down until the intervention is completed. If some damaged element has to be replaced, we must open either the sectionalising switch on the button pad or the one on the transfer unit, as circumstances require.

- In order to safeguard the cell components, care must be taken to stop foreign bodies or obstacles from entering the stations.

7.2 PROTECTION AND SAFETY DEVICES All the stations and the transfer unit are equipped with emergency stop mushroom heads for stopping the process at any moment in order to prevent accidents. If the emergency stop mushroom is used, once the incident that caused the stop has been overcome, make sure, before reactivating the cell or station, that the situation will not recur, by taking appropriate measures. Furthermore, it is advisable to take away pieces that are in the middle of a cycle whenever possible. After freeing the emergency stop mushroom it will be necessary to press the reset button so that the components return to their starting mode positions. There is also a pneumatic device at the general air input, which causes a gradual increase in air pressure when the air is first connected, thus avoiding accidents produced by the sudden input of air in the circuit. Station 3 (press) has a protection fairing to prevent accidents occurring with the press. It descends when the latter is working and goes up when the task is finished. Stations 7 and 8 (robot and store, respectively) there is a protection fairing that covers the entire station. We must be sure that all the gates are closed before running these stations. The gates should never be opened with the station running.

70

8. FAULT SIMULATION SYSTEM All the stations incorporate a Fault Simulation System fitted to the side of each station. The system consists of a lockable metal box containing 16 switches which, when operated, cause a fault in the station. There is also a connector to use the Fault Diagnosis and Virtual Repair Interactive System instead, via computer.

71

9. SETS OF PARTS FOR ASSEMBLING This refers to the sets of parts which are handled by the cell in the assembly process. Six sets are supplied, each consisting of: - 1 Body - 2 Bearings of different height - 2 Shafts of different height - 1 Aluminium cover - 1 Black plastic cover - 1 White plastic cover - 4 Screws

72

10. EC SELF-CERTIFICATION ALECOP S.COOP., hereby declares that model FMS 200 of serial nº 10/99 complies with the standards and essential requirements of directives:

- D 89/392/EEC (Royal Decree 1435/1992)-8/93. - D 73/23/EEC-D93/68 EEC. - D 89/392/EEC-D93/68 EEC RD 444/1994.

73

11. SUPPORT MATERIAL 1. FMS-200 Operating Manual. 2. FMS-200 Practical Activities Manual 3. Pneumatic Technology Study Manual. 4. Electro-pneumatic Technology Study Manual. 5. FX Automaton Programming Manual. 6. FX-2N Automaton Manual. 7. 485 Communications Card Manual 8. MEDOC Program Manual. 9. MEDOC PLUS software. By way of guidance, a list is given below of the Practical Activities aimed at developing the skills associated with the various technologies integrated into the Cell, with an explanation of their training focus..

ANNEX A

FAULTS GENERATION

1

ANNEX A: FAULT GENERATION Note: The information shown in this Annex refers to the different dysfunctions/ failures that can

be provoked in the Flexible Integrated Assembling System FMS- 200. This part of the manual should not be given to the students, so they won´t be able to associate the fault symptom with its cause.

FAULT GENERATION The Flexible Integrated Assembling System FMS- 200 offers the possibility of generating 16 different dysfunctions for each station. This means that for a complete cell with 8 stations a total of 128 faults can be generated. There are two ways of causing this faults/ dysfunctions in each station. The first way is the traditional method, by means of switches. The only way to accede to these switches is by opening the lid of the faults box present in each station, with its appropriate key. Each switch, when activated, will make a dysfunction in some components of the station. Then, the appropriate red led diode will light up. There is no limit in the number of faults tha t can be activated at the same time. After the fault is activated, the student has to analyze the system to find out which the broken component is. Then he/she will write a report, but the last step of every repairing will not be done. This would be the substitution of the broken component and the verification of the system in order to make sure that the dysfunction has been repaired correctly. This last step, as well as other possibilities, can be done with a connection of a computer to the system. The computer can be connected by the RS-232C serial line or by the CENTRONICS parallel. There are two different cables for this purpose. The connection port is located on the right side of the fault box. The SIRVAFMS program allows the programming of the faults from the PC. This program allows the following functions:

- Personalized work for each student. Every student has a personal password to have

access to the program.

- Possibility of committing a dysfunction in the system in order to analyze its effects.

- Possibility of committing faults in the system, introducing a code into the program.

These codes can be easily changed by the teacher.

- Possibility of making a virtual reparation of the component that´s suspicious of being the

cause of the fault.

- Registration of the work made by the student in a historical of reparations, in which

comments for each operation can also be included.

In the SIRVAFMS User´s manual you can find further information about this program.

STATION 1: BODY SUPPLY

2

Nº

FAULT SYNTHOM

SUSPICIOUS COMPONENT

BROKEN COMPONENT

1

The station can not be switched on

• ON Push-button • OFF Push- button • Wiring • PLC

On Push Button (XO)

2

The station does no work in automated mode

• Manual Automated switch • Wiring • PLC (Programme)

Manual /Automated switch (X2)

3

The sensor does no go down

• Cylinder of sensor • Solenoid valve Cylinder • Magnetic switch of sensor • Magnetic switch of feeder

Magnetic switch of feeder (X16)

4

The vertical cylinder of body manipulator does no go up

• Vertical cylinder of body manipulator • Solenoid valve of vertical cylinder • Vacuum switch detector • Upper magnetic detector of vertical cylinder • Wiring • PLC

Vacuum switch detector (X11)


3

Nº

FAULT SYNTHOM


BROKEN COMPONENT

5

The body is always rejected

• Magnetic detector of sensing cylinder • Wiring • PLC

Magnetic detector of sensing cylinder

6

The station can no be switched on


OFF Push-button (X1)

7

The Transfer cylinder does no return

• Transfer cylinder • Solenoid valve of transfer cylinder • Magnetic detector of transfer cylinder • Wiring • PLC

Magnetic detector of transfer cylinder.

8

The body is left without going down

• Vertical cylinder of body manipulator • Solenoid valve of vertical cylinder of body

manipulator • Solenoid valve of vacuum pads • Botton magnetic detector of vertical cylinder

of body manipulator • Wiring • PLC

Botton magnetic detector of vertical cylinder of bosy manipulator (X10)


4

Nº

FAULT SYNTHOM


BROKEN COMPONENT

9

The horizontal cylinder of the body manipulator does not go ahead and leave the body in the initial position

• Horizontal cylinder of the bosy manipulator • Solenoid valve of horizontal cylinder of bosy

manipulator • Front magnetic detector of horizontal

cylinder of body manipulator • Wiring • PLC

Front magnetic detector of horizontal cylinder of body manipulator (X6)

10

The horizontal cylinder does not go back

• Horizontal cylinder of body manipulator • Solenoid valve of horizontal cylinder of body

manipulator • Rear magnetic detector of horizontal

cylinder of body manipulator. • Wiring • PLC

Rear magnetic detector of horizontal cylinder of body manipulator

11

The vertical Cylinder of the body manipulator does no go up and the body crash against the rejector

• Vertical cylinder of transfer manipulator. • Solenoid valve of vertical cylinder of body

manipulator • Upper detector of vertical cylinder of body

manipulator • Wirirng • PLC

Upper detector of vertical cylinder of body manipulator (X7)


5

Nº

FAULT SYNTHOM


BROKEN COMPONENT

12

The Led of the detector of feeder cylinder does no light on

• Magnetic detector of manipulator • Wiring

Detector wiring (X15)

13

The body is no transfered and the vertical cylider goes down

• Transfer Cylinder • Solenoid of transfer cylinder • Wiring • PLC

Solenoid valves wiring (Y3-Y7)

14

The vacuum is no made at the pady

• Vacuum pods solenoid valves • Wiring • PLC

Vacuum pods solenoid valves (Y4)

15

The horizontal cylinder does no go ahead

• Horizontal cylinder of the body manipulator • Solenoid valve of horizontal cylinder of body

manipulator. • Wiring • PLC

Solenoid valve of horizontal cylinder of body manipulator (Y1)


6

Nº

FAULT SYNTHOM

SUSPICIOUS COMPON ENT

BROKEN COMPONENT

16

The vertical cylinder of the body manipulator does no go up

• Vertical cylinder of body manipulator • Solenoid valve of vertical cylinder of body

manipulator • Botton detector of vertical cylinder of body

manipulator • Wiring • PLC

Inputs wiring (X7-X10)

STATION 2: BEARING SUPPLY MODULE

7

Nº

FAULT SYNTHOM


BROKEN COMPONENT

1



On Push Button (XO)

2

The rotary manipulator does not move until the lift platform

• Rotary actuator • Solenoide valve of rotary actuator • Magnetic detector of supplying cylinder • Magnetic detector of rotary actuator • Wiring • PLC

Magnetic detector of supplying cylinder (X5)

3

The grippers of rotary manipulator do not open

• Grippers • Solenoid valve of grippers • Magnetic switch of rotary actuator • Wiring • PLC

• Magnetic switch of rotary actuator (X11)

4

The microswitch does provide any signal when the bearing is there

• Microswitch • Wiring • PLC

• Microswitch (X6)


8

Nº

FAULT SYNTHOM


BROKEN COMPONENT

5

The grippers of rotary manipulator do not close

• Grippers • Solenoid valve of grippers • Magnetic switch of rotary actuator • Wiring • PLC

Magnetic switch of rotary actuator (X11)

6




7

The potentiometer is measuring wrongly the height of the bearing

• Potentiometer • Wiring • PLC

Potentiometer (Analog input)

8

The potentiometer is measuring wrongly the height of the bearing

• Potentiometer • Wiring • PLC

Potentiometer (Analog input)


9

Nº

FAULT SYNTHOM


BROKEN COMPONENT

9

The station can not be switched in to the step mode

• Selector step-automatic • Wiring • PLC

• Selector step-automatic (X2)

10

The grippers of the manipulator open before they should and crash against the bearing

• Gripper solenoide valve • Bottom magnetic switch of the


• Bottom magnetic switch of the manipulator

(X13)

11

The manipulator turns before it lifts

• Solenoide valve of rotary actuator of the

manipulator • Upper magnetic detector of the

manipulator • Wirirng • PLC

Upper magnetic detector of the manipulator (X1)

12

The Led of the detector of lift cylinder does not light on

• Magnetic detector of lift cylinder • Wiring • PLC



10

Nº

FAULT SYNTHOM


BROKEN COMPONENT

13

The rotary manipulator turns in the oposite direction

• Wiring • PLC


14

The gripper of the supply manipulator does not open

• Gripper • Gripper solenoid valve • Wiring • PLC

Gripper solenoid valve (Y12)

15

The lift does no go up

• Lift cylinder • Lift cylinder solenoid valve • Wiring • PLC.

Solenoid valve of lift cylinder (Y5)

16

The manipulator goes down before it should go.

• Upper detector of lift cylinder.of body



STATION 3: HYDRAULIC PRESS MODULE

11

Nº

FAULT SYNTHOM


BROKEN COMPONENT

1

The protection cover does not

go up

• Protector cylinder • Solenoid valve of protector cylinder • Upper magnetic detector of press

cylinder • Wiring • PLC

Upper magnetic detector of press cylinder (X16)

2

The body transfer manipulator

does not turn

• Rotary actuator • Solenoide valve of rotary actuator • Vacuum switch detector • Magnetic detector of transfer cylinder • Magnetic detector of rotary actuator • Wiring • PLC

Vacuum switch detector (X10)

3


go down

• Protection cover cylinder. • Solenoid valve of protection cover • Back Magnetic switch of external

transfer cylinder • Wiring • PLC

Back Magnetic switch of transfer cylinder (X11)


12

Nº

FAULT SYNTHOM


BROKEN COMPONENT

4

The manipulator of transfer of

body does not turn.

• Rotary actuator of body transfer

manipulator • Solenoide valve of rotary actuator of

body transfer manipulator. • Vacuum switch detector • Back magnetic switch of internal

transfer cylinder. • Rotary actuator detector • Wiring • PLC

Back magnetic switch of internal transfer

cylinder.(X14)

5

The rotary manipulator does

not stop in the central position

• Central magnetic detector of the

rotary actuator. • Wiring • PLC

Central magnetic detector of the rotary actuator (X6)

6

The internal transfer cylinder

does not go ahead

• Cylinder of internal transfer • Solenoid valve of cylinder of internal

transfer • Magnetic detector of cylinder of

internal transfer • Wiring • PLC

Magnetic detector of cylinder of internal transfer (X12)


13

Nº

FAULT SYNTHOM


BROKEN COMPONENT

7

The press does not go up.

• Press cylinder • Solenoid valve of press cylinder • Bottom detector of press cylinder • Wiring • PLC

Bottom detector of press cylinder (X17)

8

The cylinder of external transfer does not go ahead

• External transfer cylinder • Solenoid valve of extrernal transfer

cylinder • Ahead magnetic detector of external


Ahead magnetic detector of external transfer cylinder (X15)

9

The press and the protection cover go down at the same

time

• Magnetic switch detector of protection

cover cylinder • Wiring • PLC

Magnetic switch detector of protection cover cylinder (X13)


14

Nº

FAULT SYNTHOM


BROKEN COMPONENT

10

The station does not run

• ON push-buttom • OFF push-buttom • Wiring • PLC

OFF push-buttom (X1)

11

The step/manual mode can not be activated

• Selector step/automatic • Wirirng • PLC

Selector step/automatic (X2)

12

The Led of the upper magnetic detector of the press does not

light on

• Upper Magnetic detector of press • Wiring • PLC

Detector wiring X16

13

Instead of the internal transfer cylender, the external one is

working

• Wiring • PLC



15

Nº

FAULT SYNTHOM


BROKEN COMPONENT

14


go down

• Protection cover cylinder • Solenoid valve of protection cover

cylinder • Front magnetic detector of external


Solenoid valve of protection cover cylinder (Y6)

15

The external transfer cylinder does not go ahead

• External transfer cylinder • Solenoid valve of external transfer

cylinder • Front magnetic detector of external


Solenoid valve of external transfer cylinder (Y6)

16

The manipulator of transfer of the body does not go ahead

• Rotary actuator • Solenoid valve of rotary actuator. • Detector of rotary actuator on the

palet position. • Detector of rotary actuator on the

transfer position. • Wiring • PLC


STATION 4: SELECTION-FITTING OF SHAFT MODULE

16

Nº

FAULT SYNTHOM


BROKEN COMPONENT

1

The module does not run in automatic mode.

• Step/ Automatic selector • Wiring • PLC

Step/ Automatic selector (X2)

2

The manipulator of load shaft in the palet does not go down

• Vertical cylinder of manipulator • Solenoid valve of vertical

cylinder of manipulator • Detector of positioning over the

palet. • Wiring • PLC

Detector of positioning over the palet (X7)

3

The vacuum pad of the manipulator does not release the shaft

• Vacuum solenoid valve. • Vacuum switch detector • Wiring • PLC

• Vacuum switch detector (X11)

4

The process stopped without any specific reason

• Detectors in general • Wiring • PLC

• Magnetic detector of indexing plate

(X23)

5 The inductive detector does not detect correctly

• Inductive detector. • Wiring • PLC

Inductive detector (X24)


17

Nº

FAULT SYNTHOM


BROKEN COMPONENT

6

The station can not be switched on

• ON Push button • OFF Push-button • Wiring • PLC

OFF push-button (X1)

7

The capacitive detector does not detect any part

• Capacitive detector • Wiring • PLC

• Capacitive detector (X25)

8

The manipulator of putting shaft in the correct position turns the shaft without any reason.

Touching detector • Wiring • PLC

Touching detector (X13)

9

The manipulator of incorrect shaft rejection does not work

• Rear magnetic detector of Horizontal Cylinder of manipulator

• Wiring • PLC

Rear magnetic detector of Horizontal Cylinder of manipulator (X16)


18

Nº

FAULT SYNTHOM


BROKEN COMPONENT

10

The Manipulator for putting shaft on the palet relieves the shaft from the top position

• Vacuum pads • Vacuum switch solenoid valve • Bottom magnetic detector of the


• Bottom magnetic detector of the

manipulator (X6)

11

The manipulator for putting the shaft in the correct position goes down with the gripper closed

• Bottom detector of vertical cylinder of the manipulator

• Wiring • PLC

• Bottom detector of vertical cylinder of

the manipulator (X15)

12

The Led of the upper magnetic detector of the vertical cylinder of loading the palet manipulator does not light on

• Upper Magnetic detector of loading manipulator1

• Wiring • PLC


13

The incorrect shaft rejection manipulator goes down before going ahead

• Wiring • PLC



19

Nº

FAULT SYNTHOM


BROKEN COMPONENT

14

The manipulator of putting the shaft in the correct position does not turn

• Rotary actuator • Solenoid valve of rotary actuator • Wiring • PLC

• Solenoid valve of rotary actuator (Y2)

15

The shafts are not delivered

• Solenoid valve of shaft

delivering. • Wiring • PLC.

Solenoid valve of shaft delivering. (Y4)

16

The vertical cylinder of incorrect shaft rejection manipulator does not go down.

• Vertical cylinder of manipulator • Solenoid valve of vertical

cylinder of manipulator • Front detector of horizontal

cylinder.. • Bottom detector of vertical

cylinder. • Wiring • PLC


STATION 5: SELECTION-FITTING OF COVER MODULE

20

Nº

FAULT SYNTHOM


BROKEN COMPONENT

1

The module does not run

- On push-button - OFF push-button - Wiring - PLC

ON push-button (X2)

2

The manipulator of load cover in the palet does not go down

- Vertical cylinder of manipulator - Solenoid valve of vertical

cylinder of manipulator - Detector of positioning over the

palet. - Wiring - PLC

Detector of positioning over the palet (X12)

3

The vertical cylinder of manipulator of rejection incorrect cover does not go up.

- Vertical cylinder of manipulator. - Solenoid valve of vertical

cylinder of rejection manipulator. - Vacuum switch detector - Wiring - PLC

• Vacuum switch detector (X23)

4

The linear encoder does not measure the height correctly

- Linear encoder - Wiring - PLC

• Linear encoder


21

Nº FAULT SYNTHOM SUSPICIOUS COMPONENT

BROKEN COMPONENT

5

The inductive detector does not detect metal material

- Inductive detector. - Wiring - PLC

Inductive detector (X24)

6

The manipulator of loading the cover on the palet closes the gripper before going down

- Bottom magnetic detector of

vertical cylinder of loading on the palet manipulator

- Wiring - PLC

Bottom magnetic detector of vertical cylinder of loading on the palet manipulator (X7)

7

The photoelectric detector does not distinguish the colors correctly

- Photoelectric detector - Wiring - PLC

Photoelectric detector (X26)

8

The horizontal cylinder of the rejection manipulator goes back before the horizontal cylinder has gone up.

- Upper magnetic detector of

vertical cylinder - Wiring - PLC

Upper magnetic detector of vertical cylinder (X21)


22

Nº

FAULT SYNTHOM


BROKEN COMPONENT

9

The horizontal cylinder of the manipulator of rejection does not go back and the cover is placed again on the indexing table

- Rear magnetic detector of

Horizontal Cylinder of manipulator

- Wiring - PLC

Rear magnetic detector of Horizontal Cylinder of manipulator (X17)

10

The station can not work in the step mode

- Selector step/ automatic - Wiring - PLC

Selector step/ automatic (X4)

11

The load manipulator does not turn through the plate and leaves the cover where it has taken it.

- Detector of manipulator

positioned over the plate - Wiring - PLC

Detector of manipulator positioned over the plate (X22)

12

The Led of the magnetic detector of position over the feeder does not light on

- Magnetic detector of loading

manipulator1 - Wiring - PLC



23

Nº

FAULT SYNTHOM


BROKEN COMPONENT

13

The horizontal cylinder of rejection manipulator does not go ahead

- Horizontal cylinder of the

rejection manipulator - Solenoid valve of horizontal

cylinder of rejection manipulator - Wiring - PLC


14

The gripper of the manipulator of putting the cover in the plate does not turn

- Gripper - Solenoid valve of gripper - Wiring - PLC

Solenoid valve of gripper (Y7)

15

The vacuum on the vacuum pads is not made

- Solenoid valve of vacuum pads - Wiring - PLC.

Solenoid valve of vacuum pads. (Y10)

16

The manipulator of loading the plate closes the gripper before go down

- Bottom detector of loading the

plate manipulator - Wiring - PLC

Bottom detector of loading the plate manipulator (X13)

ESTATION 6: SCREW HANDLING- FITTING

24

Nº

FAULT SYNTHOM


BROKEN COMPONENT

1

The module does not run

• On push-button • OFF push-button • Wiring • PLC

ON push-button (X0)

2

The insertion manipulator does not go up

• Cylinder of the insertion manipulator • Solenoid valves of the insertion

manipulator´s cylinder • Magnetic detector of the insertion

manipulator´s cylinder • Magnetic detector of the grippers • Wiring • PLC

Magnetic detector of the grippers (X11)

3

The insertion manipulator does not advance and the transfer cylinder does not return.

• Cylinders of the insertion/ transfer

manipulators. • Solenoid valves of the cilindres of

insertion/ transfer manipulators. • Magnetic detectors of the cilindres of

insertion/ transfer manipulators. • Wiring • PLC

Magnetic detector of the vertical cylinder of insertion manipulator (X6)


25

Nº

FAULT SYNTHOM


BROKEN COMPONENT

4

The insertion manipulator does not go down.

• Insertion/ Transfer cylinders • Solenoid valves of Insertion/ Transfer

cylinders • Magnetic detectors of Insertion/

Transfer cylinders • Wiring • PLC

Magnetic detector of the horizontal cylinder of transfer module (X12)

5

The insertion manipulator does not go up.

• Cylinder of the insertion manipulator • Solenoid valve of the insertion

manipulator s cylinder • Magnetic detector of the insertion

manipulator´s cylinder • Magnetic detector of the grippers • Wiring • PLC

Magnetic detector of the grippers (X10)

6

The station can no be switched on.




26

Nº

FAULT SYNTHOM


BROKEN COMPONENT

7

The station can no be switched on.

• ON Push-button • OFF Push- button • Initial conditions • Wiring • PLC

Magnetic detector of the insertion manipulator´s horizontal cylinder (X4)

8

The station does no work in automated mode

• Manual/ Automated switch • Wiring • PLC (Programme)

Manual /Automated switch (X2)

9

The transfer cylinder does not go ahead.

• Transfer cylinder • Solenoid valve of the Transfer

cylinder • Magnetic detectors of the Transfer


Magnetic detector of the transfer module´s horizontal cylinder (X13)

10




manipulator´s cylinder • Wiring • PLC

Magnetic detector of the insertion manipulator´s vertical axe (X7)


27

Nº

FAULT SYNTHOM


BROKEN COMPONENT

11

The insertion manipulator does not go ahead.




Magnetic detector of the insertion manipulator´s hozizontal axe (X5)

12

The Led of the insertion manipulator´s magnetic detector does not light on.

• Magnetic detector of the insertion


Magnetic detector of the insertion manipulator´s horizontal axe (X5)

13


• Cylinder of the insertion manipulator. • Solenoid valve of the insertion

mnaipulator´s cylinder. • Magnetic detector of the insertion

manipulator´s cylinder. • Wiring • PLC

Solenoid valve of the insertion manipulator´s (Y3) and grippers´ (Y4) cylinders.

14

Free fault.


28

Nº

FAULT SYNTHOM


BROKEN COMPONENT

15

Free Fault

16

The transfer cylinder does not go ahead.

• Transfer cylinder • Solenoid valve of the Transfer

cylinder • Magnetic detectors of the Transfer


Inputs wiring (X7- X13)

ANNEX B

ELECTRIC DIAGRAMS

ANNEX C

PNEUMATIC DIAGRAMS

ANNEX D

GRAFCET AND CONTROL PROGRAMS

ANNEX E

MECHANICAL DIAGRAMS

FM

S-2

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ANNEX F

MANUALS

Fms200

Documents

Transcript of Fms200