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1 Flexible Manufacturing System Multi FMS

Flexible Manufacturing System FMS (Fig. 1.1) developed by Festo DIDACTIC GmbH & Co. KG is a manufactory model intended for student training. This manufactory model produces bulb models which consist of a cylindric body, a bulb, a spring, and a cover.

Fig. 1.1. Multi FMS

1.1 Devices of the Flexible Manufacturing System Multi FMS

Multi FMS consists of two major machine sets: Micro FMS and FMS 50 (Fig. 1.2). These sets are divided into some smaller subsystems and both machine sets are able to operate separately. Micro FMS and FMS 50 are connected only with a sensor which is fixed on the product distribution station magazine.

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Fig. 1.2. Micro FMS ja FMS 50

The designations of the Multi FMS devices (in Estonian and in English) are presented in Table 1. Position numbers of the devices correspond to those in Fig. 1.2. Additional information is given in the Mechatronics Assistant program (Part 3).

Table 1: Designations of Multi FMS devices

Pos. nr. (Fig. 2.2.) in Estonian in English 1 Puhverkonveier süsteem Buffering conveyors 2 CNC puurimispink Turn 105 CNC latching machine Turn 105 3 CNC freespink Mill 105 CNC milling machine Mill 105 4 Kuue liikuvusastmega robot koos lisa

liikumisteega 6-axes robot with additional slide

5 Detaili sisestusmoodul Distribution station 6 Detaili testimismoodul Testing station 7 Manipulaatormoodul Handling station 8 Töötlemismoodul Processing station 9 Vision kaameramoodul Vision camera system 10 Robotiseeritud koostemoodul Assembling station 11 Riiulladu AS/RS20 station 12 Manipulaatormoodul II Handling station II 13 Sorteerimismoodul Sorting station 14 Transportsüsteem Conveyor system 15 SCADA tööjaam SCADA workstation

Micro FMS consists of a buffering conveyor system, a robot, and two CNC machines.

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Micro FMS

FMS 50 1

2

3

5

6 7

8

9

10

11

12

13

14

15

4

6

a) b) c)

Fig. 1.3. Buffering conveyor system (a), 6-axes robot with additional slide (b) and CNC milling machine (c)

Buffering conveyor system consists of three conveyors where stocks for CNC machines are located on two conveyors and products made by CNC machines are move to the third conveyor. Details are placed on the conveyor when the magazine of FMS 50 is full or this device is not in use. Products (cylindric bodies) must be removed manually.

A 6-axes robot with additional slide is used to transport the stock into the CNC machines and, to remove products. The robot delivers the products to the distribution station of FMS 50 and when it is not possible (when the magazine is full or FMS 50 is not in use), the products are returned to the buffering conveyor.

CNC machines are the CNC milling machine Mill 105 and the CNC latching machine Turn 105. Such kind of machines manufacture stocks and produce details for cylindric bodies. Manual control of CNC machines is possible via additional computer workstations belonging to the manufacturing system.

FMS 50 consists of six workstations and a transportation system where the bulb models are mounted.

The transportation system is the main device of FMS 50 that coordinates operations of the other stations. It consists of a closed loop conveyor and pallets (eight pallets). The pallets transport details or products between the six onloading and downloading positions of the conveyor. Every onloading and downloading position is placed near the workstation.

Fig. 1.4. Closed loop conveyor system

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Workstation 1 is called the detail distribution station. It consisits of the input and testing modules of the details where cylindric bodies are put into the FMS 50. After removing the detail from the magazine it goes into the testing module where detail height is measured. A defective cylindric body sorted out will not be delivered to the transportation system, it is pushed into a trough. A black cylindric body is lower than the other ones and by adjusting the second potentiometer placed on the testing module it is possible to assort black, red or silver cylindrical bodies.

Workstation 2 consists of a manipulator and manufacturing modules. The manipulator takes out the detail on the transportation system and places it into the manufacturing module where the existence of holes is tested. If there are no holes, then the cylindric body is removed from the manufacturing module. If there is a hole existing, then it is polished. After manufacturing

manipulator returns the detail to the transportation system.

Workstation 3 is a vision camera module where the camera detects defective details by checking the surface of the details. Defective details are removed in the next workstation. The camera is tightly mounted on the transportation system.

Workstation 4 is a robotized cell (mounting module) which consists of a robot and a small detail magazine. In this station the robot sorts out the defective cylindric bodies and mounts the final product. Some details which are necessary for mounting are taken out of the magazine placed near the robot. On mounting the product, first the colour of the cylindric body is detected because for a black cylinder only a silver bulb is suitable.

Next, the hole is detected below the cylinder and the bulb is placed into the hole, then the spring and finally the cover is screwed. After that the product is prepared and it is placed on the transportation system.

a) b)

Fig. 1.5. Detail input (a) and testing (b) modules

a) b)

Fig. 1.6. Manufacturing (a) and manipulator (b) modules

Fig. 1.7. Camera module

Fig. 1.8. Assembling station

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Workstation 6 is the store station AS/RS 20 where final products are collected when the output station is not turned on or channels of the product output station are full. Store station AS/RS 20 delivers final products to the transportation system when the channels of the sorting station are not full and the output station is turned on. It is possible to take out products manually when the output station is not in use. The capacity of the store station AS/RS 20 is 20 final products.

Station 6 is the product output station which consists of a manipulator (number 2) and a sorting module. The manipulator takes the product out of the transportation system and delivers it to the sorting module. In the sorting module the colour of the product is analysed by the help of the sensors and after that the product is routed to the channel of the sorting station. When the channels are full, the product output station is stopped. When the channels are unloaded, the sorting station is restarted.

Multi FMS contains a SCADA workstation which is the workplace of a factory operator. This workstation is intended for monitoring the functioning of the manufactory and the status of the parameters of the machines.

Modules of the machine FMS 50 are applicable without a transportation system (without a camera module), establishing intermodule combinations. A sample is presented in Fig. 1.11. It is necessary to follow the logic sequence when combining the modules.

Fig. 1.11. Sequence of FMS 50 machine modules without a transportation system

Materials motion in the manufacturing system Multi FMS is shown in Fig. 1.12. It shows detail inputs, detail motion in Multi FMS, places of defective detail removal and the final product. The stock for CNC machines is entered by using two conveyors of the buffering conveyor system. Additional details used to mount the final product are entered in the robotized cell (mounting module). Defective details are removed near the distribution station and mounting module. Some details are not delivered to the distribution station, these details are removed near the buffering conveyor system. After that these details may be added to the ditribution station. The final product is put out at the production output station.

Fig. 1.9. Store station AS/RS 20

Fig. 1.10. Sorting station

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Fig. 1.12. Materials motion in Multi FMS

No CNC latching machines Vision camera module and store stations AS/RS 20 in this manufacturing system are available at Tallinn University of Technology. To ensure normal functioning of Multi FMS on the side of Micro FMS, a buffering conveyor system, a robot and a CNC machine and on the side of FMS 50 transportation system, a distribution station and a product output station are necessary.

There are virtual computer models of all FMS 50 modules available at Tallinn University of Technology. These models enable students to test the control programs of the modules before loading into the real control devices. The virtual model of the robotized cell is in COSIMIR Educational software and the other models of FMS 50 in COSIMIR PLC software. The only model not available the model of Vision camera.

1.2 Control equipment

To control the modules of the FMS 50 machine, excluding the robotized cell, programmable logic controllers Siemens SIMATIC S7-300 are used .

To control the transportation system CPU 313C-2DP, ASI-Master and SIMATIC NET controller modules are used. CPU 313C-2DP has MPI and ProfiBus connection, sixteen digital inputs and sixteen digital outputs. The control program of the transportation system is loaded to this module. ASI-Master is established to connect the transportation system devices with ASI devices, which control, for example, onloading and downloading operations. SIMATIC NET has the Ethernet connection for data communication between the controller and the personal computer.

The brain of the mounting module is the system Mitsubishi MELFA CR1-571 Drive-Unit where robot control programs are loaded. It is possible to connect some additional cards for to this control system, for example, digital input/output card and Ethernet or CC-Link card. There is the SIEMENS ET200B input/output module in the mounting station. This module is established to visualise the operation of the mounting station. The device has the ProfiBus connection, twenty four digital inputs and eight digital outputs. The module is connected with the controller of the transportation system via ProfiBus.

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Final production Additional details

Defective details

Stock entering

Completed details

Defective details

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The controllers of the other modules of FMS 50 consist of CPU 313C and SIMATIC NET modules. The CPU module has the MPI connection, twenty four digital inputs, sixteen digital outputs, five analog inputs, and two analog outputs. The SIMATIC NET module has the Ethernet connection.

To control the Micro FMS machine modules, Mitsubishi MELFA CR1-571 Driver-Unit is used. This control device also controls the CNC milling machine. There is a local device in the milling machine, but the commands are given by the robot controller. The computer workplace belongs to the CNC milling machine that makes it possible to mill the other details.

Instead of programmable controllers of Siemens, excluding the transportation system controller, we may use the controllers of Allen-Bradley (e.g., CompactLogix 1769 L35E), Festo (for e.g., FEC 640) or controllers of other firms. Requirements for the controllers are as follows: a controller must have sixteen digital inputs and outputs and the Ethernet connection. At the same time, the programmable controllers of different firms may be used to control the FMS 50 machine modules. For example, some modules are controlled by Festo and others by Siemens and Allen-Bradley controllers.

Data communication between different controllers is important to guarantee normal functioning of a factory. Without communication a distribution station will not receive information about a detail. Communication between controllers occurs via digital inputs and outputs (I/O). The inputs and outputs are connected by using the laboratory cables or optical devices (transmitter and receiver). Communication between the transportation system and FMS 50 modules occurs via digital inputs and outputs.

PLC-Board

PLC-Board

PLC-Board

PLC-Board

ROBOT CONTROL

CONVEYOR CONTROL

PLC-Board

PLC-Board

PLC-Board

I/OI/O I/O

I/OI/OI/O

I/OI/O

I/O

I/O

I/O

I/O

I/O

I/O

I/OAS-INTERFASE

AS-INTERFASE

Fig. 1.13. Communication between FMS 50 modules and controllers

Communication between controllers and SCADA workstation is ensured by the Ethernet connection and at same time communication between controllers via Ethernet exists. It is very simple if all the controllers are from the same firm because then no buffering devices for translation of the information are necessary.

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Fig. 1.14. Communication between modules of FMS 50 via Ethernet

PLC - Board

PLC - Board

PLC - Board

PLC - Board

ET200 B

CONVEYOR CONTROL

PLC -Board

PLC- Board

PLC - Board

AS - INTERFACE

SWITCH

ETHERNET

PROFIBUS

SCADA