Proposal Of EDU VR1 SMART CIM – 101 V… · EDU VR1 SMART CIM-101 MTS Didactic Associate...

a

of 33

EDU VR1 SMART CIM-101 MTS Didactic Associate Companies

SAR Blended Training Concept

COPYRIGHT This document is the sole property of the MTS Didactic Group of Companies. Recipients of the document

shall not copy, divulge, or distribute it within their organization or to external third parties without the written permission from the MTS Didactic Group of Companies.

Proposal Of

EEDDUU VVRR11 SSMMAARRTT CCIIMM –– 110011

((CCoommppuutteerr IInntteeggrraatteedd MMaannuuffaaccttuurriinngg SSyysstteemm))

a

of 33





(A) 2D view

(B) 3D view

1. EDU VR1 SMART CIM-101 Probable Layout

a

of 33





Power Relay

Relay Position A

Product A Product B Relay Position B

PCB Board

Note: 1. Product A installed by Articulated Robot 2. Product B installed by Pneumatic Actuator Robot

NOTE: Illustration for visual reference only. Actual component might be different from illustration shown

a

of 33





A fully automated process demonstrates the sequences of electronics PCB production line from ASRS to manufacturing stations, towards final process known as quality inspection and sorting that will be executed within this system. - At ASRS, base material and completed PCB will be stored in respective storage bays. - Beginning at the CIM Controller, the execution is started with product selection. - Therefore the command from CIM Controller will instruct Gantry robot at ASRS to pick the appropriate PCB. - RFID Reader at ASRS to pick the appropriate PCB. - RFID would do confirmation of selected PCB at every station. - The robotics systems are programmed to insert electronic components (namely Cubic Power Relay) into the at PCB surface according to two (2) types of different PCB layout. - Vision system is configured to inspect the inserted parts condition. - At the last stop, namely sorting station, a special made actuator will pick up the rejected or incorrect PCBs based on instruction from vision system via CIM Controller.

2. EDU VR1 SMART CIM-101 Process Description

a

of 33





1. ASRS (Automatic Storage and Retrieval) Station 2. Insert Station 1 for PCB Model A with Articulated Robot Arm System 3. Insert Station 1 for PCB Model B with Pneumatic Actuator Robot System 4. Radio Frequency Identification RFID 5. Closed Loop Conveyor 6. Vision and Sorting Station 7. CIM Software 8. PLC Software 9. Main Controller

3. EDU VR1 SMART CIM-101 Station

a

of 33





Computer Integrated Manufacturing Controller (CIM Software) The CIM system should include the following packages: - Order entry, for user to key in product ID, quantity, User ID. - The CIM system has other modules such as Item Master file that allow keying of Finish goods and raw material stock info, administrator module that allows creation of user ID and accessibility. Sales order module to key in Order. Inventory and warehouse module that allow keying of opening stock and other stock transactions. - Bill of Material (BOM) Manager, for user to key in simplified production Planning & Control and maintains part quantity entered manually or automatically by ASRS. - BOM will identify the usage of raw materials for each production of finish good. Each raw material location will be stated in the Item Master file to provide info to ASRS on the material to automatically pick accordingly. - Process configuration, for user to configure product-manufacturing process (example, assembly of parts model). - Process configuration can be done by user to determine production processes, conditions and requirements, (for example models selection, quantity of production, assembly process, etc.) - Order dispatch, for user to select order to dispatch to cell controllers. After receiving order, with the BOM, the system will identify whether the raw materials required are enough. If raw materials required are available, the system will produce a list of raw materials with quantity and location to the ASRS to start production - Robot program manager, central depository for all robot programs. - The robot programs may be stored in one of the PC and they may be manually transferred to or from robot through the TCP/IP network. - Order tracking, tracks status of each order. - Order tracking in term of order status such as open order, order in progress and order completed. - Machine monitoring, tracks status of each machine in 2D real time simulation layout. - The CIM software besides providing ASRS functions, also provide HMI and machine status monitoring.

4. EDU VR1 SMART CIM-101 Specification

a

of 33





Automatic Storage and Retrieval System (ASRS) The ASRS is constructed using aluminium profile and incorporates a precision gantry robot with X, Y, Z axis and a linear slider. - The ASRS should contain minimum of 30 bays whereby each cells to accommodate pallet size of approximately 120 x 120 mm. - Each cell shall be provided with a part holder (10 holders) so that the gantry robot may directly transport the part during transferring process. - Each cell shall have part presence detecting sensor. The Gantry Robot - The gantry robot shall be designed to directly transport the part from the cells (raw material as well as finished parts) and transfer directly on to the pallet at the conveyor's working station - The gantry robot should be servo motor driven and have multiple positioning functions. - Full coverage of the ASRS cells. ASRS Functionality

Base material and finished products can be automatically retrieved and stored managed by a host computer.

A server (PC) acting as a warehouse scheduler running on open architecture using commercial SCADA software (example: Labview, Simplicity, etc) or standard Visual Basic Software or C++ programming.

Support implement Microsoft OCBC driver which enable import /export of data in standard data. Data can use/manipulated for using VBNB Script to be use in all Microsoft Office software e.g. Microsoft Excel, Access etc. It supports Microsoft SOL language, which enable database engine search/support.

The ASRS functionality software should be modular and able to incorporate into the CIM software for inventory monitoring as well as RFID identification system

Inventory monitoring system is done in the software. The ASRS framework is modular designed as such it is flexible and can be easily

expanded if required to meet future system requirements. Report: o Store in/out transaction

a

of 33





o Rack status (empty/used) location report o Store out list, by item o Inventory o Stock taking

Maintenance: o Location (facility and layout) master o Item Master o Inventory

Equipment Control: o Control robot for store in/out tasks o Interface with conveyor for store in/out

Articulated Robot Arm System This robot is used to install the cubic power relay onto the PCB board. The robot will work for individual PCB model only – Model A

The robot is a manipulator that equipped with

maintenance free AC motors, which have electromechanical brakes.

To wiring the robot, integrate, configure and program the robot into the CIM system.

To design and supply appropriate EOAT for the robot to execute insertion application.

EOAT: Pneumatic actuated with payload 1Kg or better The robot can be manually operated in any one of the

following ways: o Axis by axis i.e. one axis at a time o Linearly, i.e. TCP (Tool Center Point) moves in a linear path relative to one of

the coordinate systems mentioned above. o Reoriented around the TCI.

Robot Controller and Teach Pendant:

Open system architecture. Computer unit base on industrial PC Pentium-M processor 1.2 GHz and 512MB memory (or better) USB port for

connection of external mass memory Possibility to mix field buses of different brands Cooling system (no filter needed in normal industrial environment) Maintenance free UPS for power failure backup (with batteries) Compact cabinet with dimension of 850 x 700 x 700mm All operation and programming can be carried out using the teach pendant.

a

of 33





7. 7" large touch screen with color display OS Windows CE.NET Intel Strong ARM processor RH and LH support Standard 15m cable between robot

control cabinet Standard 10 m teach pendant cable (Max. 20m) Weight approximate 1 kg Jogging I teaching of robot must be using a "joystick"

Manipulator Arm

Minimum Reach 800mm Minimum Payload of 4kg Supplementary load on upper arm: 1kg Position repeatability +/-0.03mm 6 number of axis with brakes TCP Velocity of 2.5m/s Axis movement:

o Axis 1: 360° o Axis 2: 200° o Axis 3: 280° o Axis 4: unlimited o Axis 5: 240° o Axis 6: unlimited

Control specification

C base programming software Dedicated software for quick acceleration at sharp corners Control motion with Linear and reorientation at any point within the working range External signal user free 16 digital inputs and 16 digital outputs or more Main memory up to 256MB and 256 flash disk memory, specially designed for high

speed memory transfer

Parts Feeding Unit

Single feed at one time Proximity sensor for work presence Zero positioning device

a

of 33





Pneumatic Actuator Robot System

This robot is used to install the cubic power relay onto the PCB board. The robot will work for individual PCB model only – Model B

PLC control The robot is a manipulator that equipped with

maintenance free actuator. To wiring the robot, integrate, configure and

program the robot into the CIM system. To design and supply appropriate EOAT for the

robot to execute insertion application. EOAT: Pneumatic actuated with payload 300g or

better The robot can be manually operated in any one of

the following ways: o Axis by axis i.e. one axis at a time o Maintenance or Auto Mode

Robot Controller and Teach Pendant

PLC come with console and software With network linking and RS 232 serial communication or better Emergency stop for safety Good ventilation at the PLC control unit All programs must be accessible by using programming console.

Actuator Arm

Minimum Payload of 2kg Supplementary load on upper arm: 500 g Position repeatability +/-0.03mm Minimum 2 number of axis

a

of 33





Radio Frequency Identification (RFID) System Read I Write Head RFID Read/Write is used to update the status of the product after every process until it comes out as a finish good.

RFID Read/write head of at least 500mm detecting range shall be used. The sensor and the processor may be separated or integrated. There shall be a standard communication port like series port, IR Communication or RS-485 etc providing the linking to the Main controller.

RFID System

PC based. The material is to be tracked after the first machining process till sorting to respective

predefined finished product bays. Each station are equipped with read/write heads All RFID Read/Write heads are connected to PC via standard communication protocol. Measuring about 38mm x 45mm, the reader module is ideal for battery operated

handheld readers, mobile devices and printers. With a standard RS232 cable plus a USB connector, it is a ready "plug and play" product for desktop solution. The module also comes in RS422 and RS485 interfaces.

Closed Loop Conveyor System

Powered for accumulation of parts - Pallets are able to accumulate by using roller chain controlled by inverter. Chain will continue moving even when pallet is stopped by stopper cylinder. But, the center roller of chain is free rotating to give very low friction between pallets and rollers.

Closed loop system

- It is a closed loop system, consists of 4 modules conveyor with diverter at each corner. Pallet will be circulated flow on the conveyor and always in the same orientation.

a

of 33





Handle standard pallet in individual parts

Pallet size is approx. 200x200mm, which made by aluminium material c/w locating bush for locating purpose.

Pop-up and Pop-up transfer unit should be provided for stopping and routing of pallets

parts

- Pop-up and Pop-up transfer unit would be provided. Stopper cylinder with locator unit to stop and separate the pallets.

Heavy duty stopper cylinders with roller and shock absorber at end of cylinder

- For better application, heavy-duty stopper cylinder with roller and shock absorber at end of cylinder should be provided. This cylinder should be control by individual valve.

Operation from system individual PLC

Convey parts to and from system module

Provided for added operation

All added operation (vision checking station, insertion station and sorting station) is all linked and integrated with the conveyor system.

Double free chain drive-to running flightless

Use free roller chain for pallet accumulation. Chain beam extruded aluminium, channels, with guides to support chain. Using standard aluminium profile for free roller chain c/w side profile and PE Guide to guide pallet. Each conveyor has 2 legs support, which constructed by aluminium profile.

Pneumatic pop-up unit for stopping of pallet

- For every pop-up unit for stopping pallet, 2 sets of locator unit will be provided for accuracy stopping position purpose. Locating pin will locate into locating bush at pallet and lift up for loading and unloading part.

Pneumatic pop-up Transfer unit for directing pallet direction at 900 bend.

- There are 4 sets of diverter unit at corner to transfer pallet into each conveyor. The design will be using single motor to drive belt to transfer pallet to the next conveyor.

One operation box for each pop-up and pop-up Transfer unit with

a

of 33





manual/automatic mode selector

- Operation box c/w switch to select manual/automatic mode, to control individual pneumatic actuator will be provided.

Motor and gear reducer- AC motor and gear reducer sized to provide conveyor

speed of 6-10 m/s (min)

Mounting support-adjustable height legs (850mm to 950mm)

- Pallet height from floor will be 900mm. Level adjustable (footing) will be provided for height adjustment approximately 100 mm.

Sensors and valves-pallet sensors and solenoid valves would be included in the PLC

Panel and operation of Pop-up stoppers and Pop-up Transfer unit Control panel provided with "On", "Off", "E stop", "Auto/Manual" and other press buttons and switches.

- Control panel has individual press button for On/Off, E-stop and switches for auto/manual mode and pneumatic actuator control. Control box for conveyor located at below conveyor, control the operation of the conveyor, and provide means of interlocking with the Vision system, Robot, and ASRS. PLC housed in the control panel, is networked to the main server for CIM operation.

Vision and Sorting System

Type: High speed No of required camera: 1 Possible camera: 2 No of pixel: 512 x 484 (H x V) or equivalent No of scenes: 32 Image storage function: Max 35 images stored Parallel 1/0: min 13 inputs I 22 outputs Power supply voltage: 20.4 to 26.4 VDC

Sensing Capabilities: Size, position, defect, characters,

angle, quantity, shape, classification and brightness.

Windows based software to communicate with CIM system on object recognition.

Sorting System o Electro-pneumatic pick & place

a

of 33





actuator o 2-axis operation with single gripper o Rod less cylinder for both axis o Sequence controlled by PLC o Compartment cover: clear o Cable protection: cable carrier o Mounting bracket: for camera installation

Rejected bin: 1

o Working size: Approx: 500 x 250 x 300mm

Main Controller

Main Controller should have both Standard Mode and Experimental Mode

PLC requirements: o 1/0: Sufficient points + 20% spare o Peripheral port o RS232 port o Power supply unit o expansion unit o Memory cassette o Touch Panel Color TFT or computer desktop o QVGA. 640 x 480 pixe!s o Memory 60MB

Tower Light- 3 colors User Operation box Safety features

o Alarm buzzer o Emergency stop o Safety Fencing o Safety door switch

CPU requirements:

o Control method: Stored program method o 1/0 control method: Cyclic scan and direct output/immediate interrupt processing o Programming language: Ladder- diagram programming o Instruction length: 1 step per instruction, 1 to 4 words per instruction o Number of instructions: 162 (14 basic, 148 special instructions) o Instruction executions times: Basic instructions: 0.375 to 1.125 !JS o Special instructions: 17.7 μS (MOVinstruction) o Overseeing time: 0. 70 ms

a

of 33





o Mounting structure: No Backplane (Units are joined horizontally using connectors) o Mounting: DIN Track mounting (screw mounting not possible) o CPU Unit built-in DC input points: 16 o 110 allocations: 1/0 is automatically allocated in order from the Unit nearest to the CPU

unit.

a

of 33





EDU VR1 CIM-110 (For Nakhon Si Thammarat Seaboard Industrial College, Thailand) Station 1: Automatic Storage & Retrieval Sub-system

5. EDU FMS / CIM References

a

of 33





Station 2: Material Handling Sub-system - Conveyor - Pallet Station 3: Flexible Manufacturing System

• - 6-axis articulated robot • - EDU VR1 Mill-TB

(EDU CNC Milling machine with built-in troubleshooting board)

a

of 33





Station 4: Vision Inspection Sub-system Station 5: Central Control Sub-system - SCADA - PLC - RFID

a

of 33





On-site system commissioning, tuning & training

a

of 33





a

of 33





EDU VR1.5 CIM (For Salman University, Al Kharj, Saudi Arabia)

a

of 33





a

of 33





EDU VR1 CIM-110 (For University Malaysia Pahang, UMP) On-site installation and commissioning

a

of 33





Application training

a

of 33





EDU VR1 SMART CIM-101 (For MJII (formerly KKTM Beranang), Malaysia)

a

of 33





Automated System (AR Finisher) For Automated Enforcement System

a

of 33





EDU VR2 – CIM

Auto Storage / Retrieve System (ASRS)

Vision Inspection System Assembly System

Materials transfer - FMS (lathe, Mill & robot) / Conveyor

a

of 33





EDU - CIM (with Custom Made Machine)

Auto Storage / Retrieve System (ASRS) Custom made XYZ engraving machine with Siemens 802C

Inspection System Assembly System

a

of 33





Computer Integrated Manufacturing (CIM) REFERENCE with EDU Machines In ITE College Centre EDU – CIM CKD

a

of 33





Computer Integrated Manufacturing (CIM) REFERENCE with EDU Machines

EDU VR2 - CIM Setup at Islamic University Yogyakarta, Indonesia

EDU VR1 - CIM Setup at Perlis University, Malaysia EDU VR1 - CIM Setup at Rajaphat University, Thailand

EDU VR1 -CIM Setup at ITE Yishun with Spinner E-MILL, Singapore

EDU VR1- CIM Setup at ITE Macpherson with Spinner E-MILL, Singapore

a

of 33





Other CIM / FMS Models

EDU VR1 – CIM with CNC router

EDU VR1 – CIM with EDU Mill VR1.5

EDU IMS – Integrated Modular System

Proposal Of EDU VR1 SMART CIM – 101 V… · EDU VR1 SMART CIM-101 MTS Didactic Associate...

Documents

Transcript of Proposal Of EDU VR1 SMART CIM – 101 V… · EDU VR1 SMART CIM-101 MTS Didactic Associate...