FMS 100 Manual AS-RS

FMS 100 Manual AS-RS

FMS 100

Manual

AS-RS

2

Order-NR.:

Designation FMS100_AS_RS_A015

Printed: 02.04.2003

Autor: Schober

Graphics: Schober

Layout: Schober

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

Internet: www.festo.com/didactic e-mail: [email protected]

This manual, all text and illustrations contained included, is protected by copyright. Any utilisation outside the limits of the copyright law and other than training purposes are not permissible without our definite approval. This applies in particular to reproductions, operations, translations, micro filming and the storing and processing into electronic systems. Parts of this manual may be copied by the authorised user, exclusively for teaching purposes. Distribution of this documentation, as well as reproduction, use and spread of its contents is prohibited, insofar not permitted explicitly. Offences are liable to compensation. All rights reserved, especially the right to execute registrations concerning patents, designs for use and patterns.

© Festo Didactic GmbH & Co.KG • FMS 100

1. Intended use

The User Manual must be to hand at all times. Keep it close to the machine.

This installation was developed and manufactured only for use in basic and further training in the fields of automation and communications. The training company and/or the training staff must ensure that the trainees observe the safety precautions described in the accompanying manuals.

Furthermore this manual describes setup and possible uses of the singular stations.

It contains all information and data required for commissioning, maintenance and operation.

Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any third parties occurring when the installation is used for any purpose apart from training, except Festo Didactic has caused such injury or harm intentionally or by grossly negligence.

The manual is divided into four parts:

• Part A

In addition to technical data, Part A contains an overview of the possible uses of the stations.

• Part B

Part B contains some exercises and the solutions for this exercises (Not available for each station).

• Part C

Part C contains the pneumatic and electrical diagrams for the station and the listing of the control programs (Not available for each station).

• Part D

Part D contains data sheets and technical information about the electrical and electronic modules used.

© Festo Didactic GmbH & Co.KG • FMS100

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List of applicable standards and regulations

The list below provides an overview of the most important standards and regulations relating to mechanical, electrical and safety-engineering design and production.

• DIN EN 292 -Machine safety

• DIN EN 60204 - Electrical equipment of industrial machines

• DIN VDE 0113 - See DIN EN 60204

• DIN 40719 - Circuit documentation

• VDI 2853 - Technical safety requirements concerning the building, equipping and operation of industrial robots

• VDI 2853 - Technical safety requirements concerning automated production systems

• VDI 2411 - Terms and explanations in conveying and handling

• VDI 2860 - Assembly and robotics - terms

• VDI 2861 - Assembly and robotics - characteristic quantities

• DIN 19245 - PROFIBUS Part 1-3

As far as possible, the System is maintenance-free. All bearings are lubricated for life. The installation was designed in such a way as to keep the number of wearing parts to a minimum. This does not include machines that are part of optional expansions (such as industrial robots).

At this point we would like to point out that this manual and the concept of the operating instructions for a Flexible Training System of this type are regularly updated. To ensure that the instructions are ever more user-friendly, you would help us a great deal by passing on your suggestions for improvement. Please let us know of your suggestions, corrections or ideas, either in writing or via telephone:

+49(711-3467-0)

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© Festo Didactic GmbH & Co.KG • FMS 100

2. Contents

1.

Intended use ___________________________________________________ 3

2.

Contents_______________________________________________________ 5

3.

Introduction ___________________________________________________ 11

3.1.

General_____________________________________________________ 11

3.2.

AS-RS station________________________________________________ 12

3.3.

Didactic structure ____________________________________________ 13

3.4.

Scope of tasks of the stations __________________________________ 14

3.4.1.

Mechanics ______________________________________________ 14

3.4.2.

Pneumatics _____________________________________________ 14

3.4.3.

Electrics ________________________________________________ 14

3.4.4.

Informatics______________________________________________ 14

3.4.5.

Bus technology __________________________________________ 14

4.

General safety instructions_______________________________________ 15

4.1.

Use according to regulations ___________________________________ 15

4.2.

Handling the system __________________________________________ 15

4.2.1.

Dangers in handling the machine ____________________________ 15

4.2.2.

Safety precautions in standard operation _____________________ 15

4.2.3.

Dangers due to electric current _____________________________ 16

4.2.4.

Dangers due to pneumatic energy ___________________________ 16

4.2.5.

Maintenance – Servicing – Malfunction removal ________________ 17

4.2.6.

Organisational measures __________________________________ 17

4.3.

Personnel___________________________________________________ 17

© Festo Didactic GmbH & Co.KG • FMS 100

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Contents

6

4.3.1.

Notes on personnel _______________________________________ 17

4.3.2.

Training operations _______________________________________ 17

4.3.3.

Outside training operations ________________________________ 17

4.3.4.

Safety symbols __________________________________________ 18

5.

Commissioning ________________________________________________ 19

5.1.

Transport ___________________________________________________ 19

5.2.

Set up______________________________________________________ 20

5.2.1.

General information ______________________________________ 20

5.2.2.

AS-RS station____________________________________________ 20

5.3.

Commissioning ______________________________________________ 23

5.3.1.

Pneumatic commissioning _________________________________ 23

5.3.2.

Electric commissioning ____________________________________ 23

5.3.3.

Connecting communication cables___________________________ 24

5.4.

Connection Profibus __________________________________________ 24

5.5.

Start up the system ___________________________________________ 25

5.5.1.

Start up conditions _______________________________________ 25

5.5.2.

general information_______________________________________ 25

5.5.3.

Adjust AS/RS station______________________________________ 26

5.5.4.

Soldering station _________________________________________ 26

5.5.5.

Robot assembly station ___________________________________ 26

5.5.6.

Hydraulic station _________________________________________ 27

5.5.7.

Adjust transport system ___________________________________ 27

© Festo Didactic GmbH & Co.KG • FMS 100

Contents

5.5.8.

CNC-coupling station______________________________________ 28

5.5.9.

Vision station____________________________________________ 28

5.5.10.

Start up cell control and COSIMIR CONTROL _________________ 28

5.5.11.

Start-up of processes ___________________________________ 29

5.6.

Shut down the system_________________________________________ 29

6.

Operation_____________________________________________________ 31

6.1.

General operation notes _______________________________________ 31

6.1.1.

Behaviour rules __________________________________________ 31

6.1.2.

Operation rules __________________________________________ 31

6.2.

Process description___________________________________________ 32

6.2.1.

AS-RS station____________________________________________ 32

6.2.2.

General_________________________________________________ 33

6.3.

Order codes AS/RS 40 PLC – COSIMIR CONTROL ___________________ 34

6.4.

Operation panel______________________________________________ 35

6.5.

Reset mode _________________________________________________ 37

6.6.

Automatic mode _____________________________________________ 37

6.6.1.

Start automatic mode _____________________________________ 37

6.6.2.

Stop automatic mode _____________________________________ 37

6.7.

Teach mode _________________________________________________ 38

6.7.1.

Example teach a position __________________________________ 41

6.7.2.

Load positions into controller_______________________________ 42

6.8.

COSIMIR CONTROL AS/RS Manager______________________________ 43

© Festo Didactic GmbH & Co.KG • FMS100

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Contents

8

6.8.1.

Modify function __________________________________________ 45

6.8.2.

Retrieve function / Search for part number ____________________ 48

6.8.3.

Retrieve function / retrieve shelf direct _______________________ 50

6.8.4.

Zoning _________________________________________________ 52

6.8.5.

Store function / search for empty shelf _______________________ 53

6.8.6.

Store function / store shelf direct ___________________________ 55

6.8.7.

Move part_______________________________________________ 57

6.8.8.

First time init ____________________________________________ 59

6.8.9.

Edit Product list __________________________________________ 61

6.8.10.

Trouble shooting / AS-RS-Manager ________________________ 64

6.8.11.

RETRIEVE mode / RETRIEVE SHELF DIRECT __________________ 65

7.

Technology ___________________________________________________ 67

7.1.

drawings ___________________________________________________ 67

7.2.

Modules in use ______________________________________________ 68

7.2.1.

Palette reception _________________________________________ 68

7.2.2.

First time list ____________________________________________ 70

7.2.3.

Telescope_______________________________________________ 72

7.3.

Technical datas ______________________________________________ 73

8.

Electrical system _______________________________________________ 77

8.1.

Power supply ________________________________________________ 77

8.2.

Controller ___________________________________________________ 78

8.2.1.

Controller design IPC______________________________________ 78

© Festo Didactic GmbH & Co.KG • FMS 100

Contents

8.3.

Wiring______________________________________________________ 79

8.3.1.

I/O-Components _________________________________________ 79

9.

Trouble-shooting_______________________________________________ 81

© Festo Didactic GmbH & Co.KG • FMS100

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Contents

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© Festo Didactic GmbH & Co.KG • FMS 100

3. Introduction

3.1. General

This user-defined installation contains parts of the FMS 100 system, mixed together with other components. The installation, thus created, is explained in the following operational manual and the respective station manuals.

In the development of the system, various production technologies have been combined into one installation. The aim of the installation is the increase of competence, from a simple setting of examples up to a complete production process, including all features.

Additionally, to technical and social competence, the comprehension of the process and the interaction of the respective components appear in clear presentation.

This manual describes working with the FMS system. Everything is explained and described for the operation of necessary events. With the help of graphics or pictures a simple communication should be obtain.

Complete operating instructions which explain the processes of the system are available for working with the system. Station manuals are also available for the individual stations.

Additionally to technical and social competence, the comprehension of the process and the interaction of the respective components appear in clear presentation.

Festo Didactic succeeded in using the most updated industrial hard- and software for this model production.

© Festo Didactic GmbH & Co.KG • FMS 100

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Introduction

The automatic storage/retrieval system is designed to store, retrieve and relocate workpieces.

The storage system can be equipped with empty or full pallets at the beginning. The assignment of storage locations must agree with the assignment stored in the stock computer.

Pallets can be stored, retrieved or relocated, that is, collected from its current location and to the transport system. If a pallet is available at the transport system, this can be re-stored.

During relocation, the selected pallet is temporarily stored at a free storage location.

The second pallet is then stored at the first location. The temporarily stored pallet can now be stored at the former location of the second pallet.

The control for the station is put in a control cabinet of its own which is assembled in the basic rack of the station.

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© Festo Didactic GmbH & Co.KG • FMS 100

Introduction

The installation is structured, to enable methodical learning, i.e. from single use of modules to the complex and complete installation. Perhaps even in combination with further systems.

For example, it is possible to pick out a single module to start with the first steps, e.g. the robot.

• First the mechanical assembly is considered. The robot’s radius of action requires integration into the location of the robot.

• The following step could be the connection of all cables required for operation and the set-up of the robot.

• Moving the robot and teaching the required positions are the first real operations with the robot, which introduces the user how to deal with the teach-box.

• The robot’s programming can be started, as soon as the robot can be moved by the teach-box. Small programs, which can be created by using the

Cosimir/Cosirob software, are expandable for the complex programs.

• Orders to further stations and from other controls can be installed in the programs.

Once the learning process of this module has been concluded, these learning steps can be transferred to the next module. As soon as all of the modules have been processed individually, the modules can be interconnected and the programs can be adapted. A complete production process can be simulated.

This is an ideal training area for the professional practice of mechatronis, as well as all of the technical ranges (mechanical, electrical and pneumatic processes) are represented in a simple and clearly way, concerning each one of the modules and the complete system.

© Festo Didactic GmbH & Co.KG • FMS100

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Introduction

3.4. Scope of tasks of the stations

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

3.4.1. Mechanics

• Obtaining basic mechanical skills about the assembly of basic modules

• Obtaining complex mechanical skills about the assembly of a complete station or complex modules

• Assembly provides instructions about the technical connections between the various components

3.4.2. Pneumatics

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

3.4.3. Electrics

• Obtaining electrical knowledge of reading a circuit diagram, concerning the wiring of sensors and valves

• Functional understanding of the individual modules e.g. in case of error detection, by means of a circuit diagram and a measuring device

3.4.4. Informatics

• Understanding of programs receiving an insight by controlling the individual components of the programs

• Changing and improving programs recognising and removing errors in a complete program

• Writing new programs new programs can be written by combination of the skills obtained in the steps before.

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• Instructions in the various bus technologies avoidance to gain intimate knowledge about the various bus technologies is made impossible by working with the programs

© Festo Didactic GmbH & Co.KG • FMS 100

4. General safety instructions

4.1. Use according to regulations

This installation has been developed and produced exclusively for training purposes in the fields of automation and communication. The training company, as well as the instructors have to ensure, that the trainees pay strict attention to the safety precautions, as described in the accompanying manuals.

Festo Didactic accepts no liability charges for possible damages to any trainee of the training company and/or further third parties, which might occur during use/operation of the installation, if it is not part of a real training situation; except

Festo Didactic caused such damages deliberately or by negligence.

4.2. Handling the system

Due to the product liability law and various EC-directives, the following directions are required and are to be strictly observed by the operator.

4.2.1. Dangers in handling the machine

The installation has been constructed technologically up to date and in conformance with the recognised rules of safety engineering. Nevertheless, during operation it is possible that harm might be caused to the user or third parties or that the installation or other property might get damaged. Therefore, the installation has to be handled according to specified operational use in perfect technical condition only.

Safety endangering malfunctions can not be tolerated during training and have to be removed immediately.

4.2.2. Safety precautions in standard operation

Put the installation into operation only, once all of the protection settings are completely functional.

At least, before starting operation, check the installation for externally visible damages and for the reliability of the safety devices.

Do not grip into the installation while in operation.

Before circuit construction, circuit disassembly and circuit modification: switch off air pressure and power supply.

General safety regulations are to be observed: DIN 58126 and VDE 0100.

© Festo Didactic GmbH & Co.KG • FMS 100

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General safety instructions

4.2.3. Dangers due to electric current

As soon as maintenance is completed, check the function reliability of the safety devices.

Only trained experts in electric or electronic engineering are permitted to carry out work on the electric supply system.

The terminal boxes are to be kept closed at all times. Access must be permitted only under supervision of a member of the training staff.

Do not activate electric limit switches manually during fault search. Tools are to be used.

Only low voltage 24VDC is to be used.

4.2.4. Dangers due to pneumatic energy

Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt air pressure supply immediately.

Caution! When the air pressure supply is activated, cylinders may move in or out.

Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In this case, keep on holding the end of the tube.

Do not exceed the permitted operating pressure. See data sheets.

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© Festo Didactic GmbH & Co.KG • FMS 100

General safety instructions

4.2.5. Maintenance – Servicing – Malfunction removal

Carry out adjustments and inspections as instructed, in accordance with the specified intervals.

Secure the compressed air and electricity supplies to prevent unintentional start-up.

During inspections, maintenance and repair work, the machine must be deenergised, de-pressurised and secured against unexpected restart.

All screw connections released during maintenance, inspection or repair work must be checked to ensure correct re-tightening.

4.3. Personnel

All existing safety devices must be checked at regular intervals.

4.3.1. Notes on personnel

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

• Activities during training operations

• Activities outside training operations

4.3.2. Training operations

Trainees are permitted to work with the machine only under strict supervision of an experienced person or an instructor.

Activities of trouble-shooting and fault correction are to be checked by the instructor. Special care should be taken regarding safety aspects.

4.3.3. Outside training operations

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

© Festo Didactic GmbH & Co.KG • FMS100

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18

General safety instructions

In this manual the following danger designations and signs are being used:

This symbol indicates an immediate threat to a persons health or life.

DANGER !

Failure to pay attention to this symbol may result in serious health damage, which may even lead to life-threatening injuries.

This symbol emphasises important information for correct machine handling.

IMPORTANT

Failure to pay attention to this symbol may result in damages to the machine or to its surroundings.

This symbol indicates operational tips and especially useful directions. i

INFORMATION

This symbol assists you to make optimal use of all of your machine’s functions.

© Festo Didactic GmbH & Co.KG • FMS 100

5. Commissioning

5.1. Transport

i

Care is to be taken that the transport of the stations is to be executed only by a suitable transport vehicle. The weight amounts up to 500 kg, depending on the station.

The route of transport is to be cleared in advance, to be accessible to the transport vehicle. Installation of warning signs or barriers may be required.

The transport boxes are to be opened with care, as additional components, such as computers may be contained in the delivery, which are to be protected from falling out.

Once the transport box has been opened and the possibly contained additional components removed, the station can be taken out to be transported to its destination by means of two fork-lifts or one fork-lift truck.

Please check the stability of all of the profile connectors by means of an Allen key size 6. The connectors may have come loose during transport, due to inevitable vibration.

Pay special attention to all overhanging components. Sensors and similar small parts are very easily damaged in case of improper transport.

The stations are not to be picked up by or even under the mounted feet – increased risk of becoming trapped or contused.

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© Festo Didactic GmbH & Co.KG • FMS 100

Commissioning

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The installation is to be set up in a frost-free room with maximum relative air humidity of 70%.

In countries with an atmospheric humidity over 70% and temperatures above 25 degrees Celsius, the premise is to provide an air-conditioning system for constant surrounding conditions.

To comply with the levels of the regulatory guidelines, sources of electrical interference such as welding plants, large motors and contactors are to be checked for electromagnetic compatibility in advance and screened where necessary.

To ensure faultless operation a load-bearing floor is required to avoid settling.

Allow sufficient distance between the installation and the wall of the room.

Any dust originating from construction work has to be kept off the installation (by covering).

The AS-RS station can be built up only if the conveyor system stands on its final place and the commissioning for the conveyor system has been carried out.

The installation must be aligned with a spirit level in such a way that all shelves are in one horizontal plane. To do this it may be necessary to place supports beneath some points of contact if the floor is very uneven.

If the AS/RS station is to be used with other stations, the store must be locked together with the frame of the conveyor system. With the aid of the guides it is possible to position it relatively precisely in relation to the conveyor system, now the stations are secured against shifting during operation. This guarantees precise transport system of the work-pieces.

© Festo Didactic GmbH & Co.KG • FMS 100

Commissioning

For a more simple room planning the complete installation design is shown in the following. The AS-RS station is to line up that a fault-free workpiece handing over can take place.

Installation design FMS system

© Festo Didactic GmbH & Co.KG • FMS100

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Commissioning

Dimension drawing FMS system

Position AS-RS station

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© Festo Didactic GmbH & Co.KG • FMS 100

Commissioning

5.3. Commissioning

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

The AS/RS station has to be mounted on operating position 1 of the transport system, utilising the included profiles. Afterwards, the distance of the AS/RS station is fixed in such a way, that the telescopic transfer unit is able to move in extended status over operating position 1. At this point, screw and lean the profiles lightly onto the basic frame of the transport system station, by means of the angles. Align the AS/RS station by means of a spirit-level and tighten the connector profiles afterwards.

It may be possible, that the transfer position of operating position 1 must be taught corrected.

5.3.1. Pneumatic commissioning

The mechanical construction must be finished. At the beginning the stations have to be attached to the pneumatic system of the room. In most cases the maintenance unit is on the profile plate of the station. The coupling has a 5 mm nominal diameter.

If the available system is equipped with 7.9 mm nominal diameter, it is possible to change the coupling of the maintenance unit with a greater one. (reducer 1/8 on 1/4 necessary). If this has been carried out, the stations can be provided with 6 bar and the pneumatic commissioning is realised.

The station must be provided with electrical voltage now.

The control cabinets are provided with a voltage of 230 V. The delivered cable has a completely protected norm plug, this must be plugged into an electrical socket protected sufficiently. Distribution strips are, enclosed to this also for the connection of other stations. If an extension for the cable is necessary for the distribution strip, this can to be executed only by a trained expert. The electrical socket must be protected, corresponding to the customer.

The power supply (24 VDC) of the sensoric and the actuators of the station is provided in each case by means of a 2-pin cable. The voltage supply is a 24 V power supply unit, contained in the control cabinet or somewhere in the station.

Some of the stations are provided with a voltage of 380 V. The enclosed cable has a completely protected norm plug, this must be plugged into an electrical socket protected sufficiently. If an extension for the cable is necessary for the distribution strip, this can to be executed only by a trained expert. The electrical socket must be protected, corresponding to the customer.

© Festo Didactic GmbH & Co.KG • FMS100

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Commissioning

5.4. Connection

There is only one communication line to connect the AS/RS, the Profibus ring. The hole Profibus system with addresses and a overview about all stations, is explained in the main manual.

Previous station

Profibus with IPC

Following station

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

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

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© Festo Didactic GmbH & Co.KG • FMS 100

Commissioning

5.5. Start up the system 5.5.1. Start up conditions

For the FMS system a first commissioning at Festo was already executed. The following explanation is for the commissioning at customer’s side.

Before starting the cell control, the work-pieces already have to be positioned on the conveyor belt of the transport system. For the work-piece carriers it is important:

• Not to stand in any operating position

• All of them, one after another

• Frontally of the vision station

• Max. 10 carrier

This start-up situation applies to each production start-ups and is to be re-entered at each production start-up.

It is required, that all of the stations are set up, aligned and adjusted, before starting the system. All of the transfer and assembly positions have to be adjusted or taught.

The first start-up and teaching of each station is explained in detail in the station’s manual and has to be executed before.

• Switch on distribution strips

• Activate air supply for all stations min. 4 bar – max. 6 bar

• Activate master switch of the AS/RS station AUTO/MAN switch on AUTO

• Activate Power supply unit of soldering station AUTO/MAN switch on AUTO

• Activate power supply unit of the robot assembly station AUTO/MAN switch on

AUTO

• Activate power supply unit of hydraulic station AUTO/MAN switch on AUTO activate hydraulic aggregate

• Activate distribution strip of CNC-coupling station AUTO/MAN switch on AUTO

• Do not activate the key switches of the CNC machines and the master switch of the robot

• Unlock the emergency-off switch of all of the stations and confirm with the QUIT button.

• Confirm Emergency board of CNC-coupling station with key switch

• Switch on the PC - COSIMIR CONTROL

• The switch of the teach-box of the robots is to be set to Disable.

• Activate the master switch of the CNC machines and the Drive units, once all of the controls have been started up.

• Switch on PC´s of CNC-machines – WIN NC is started automatically

• The key actuators of the CNC machine is to be set to FMS mode.

© Festo Didactic GmbH & Co.KG • FMS100

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Commissioning

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5.5.3. Adjust AS/RS station

Danger of collision. In case the transfer handling is very close to or in imminent danger of collision with the transport system station, it is to be moved out of the danger area manually. The axis are to be moved very slowly only, otherwise voltage induction may occur.

• If a palette is positioned in the transfer unit, it has to be removed.

• The selector switch has to be in auto-mode

• If the RESET lamp is flashing, start the adjustment operation by using the

RESET button.

• If the AUTOMATIC ON lamp is flashing, use the AUTOMATIC ON button to activate the station’s automatic mode.

Danger of collision. The arm of the robot has to be removed from any danger area of the CNC machine.

• Possibly existing palettes and work-pieces have to be removed.

• The grippers have to be available at their place of destination.

• The cleaning sponge of the soldering tip should be humid (not wet).

• Sufficient soldering zinc has to be available.

• The magazines have to be stocked up.

• Activate the controller of the soldering system. The soldering iron requires approx. 1 min. to reach its operating temperature.

• Switch on robot drive unit

• Start the adjustment operation by using the RESET button.

• Use the AUTOMATIC ON button to activate the station’s automatic mode.

5.5.5. Robot assembly station

Danger of collision. In case the robot is very close to or in immediate danger of collision, the robot (robot-arm) is to be removed manually from the danger area.

• Possibly existing palettes and work-pieces have to be removed.

• The magazines are to be stocked up.

• Switch on robot drive unit

• Start the adjustment operation by using the RESET button.

• Use the AUTOMATIC ON button to activate the station’s automatic mode.

© Festo Didactic GmbH & Co.KG • FMS 100

Commissioning

Danger of injury. Work-pieces or alien elements possibly existing in the hydraulic press have to be removed after conclusion of the adjustment process, only.

• Possibly existing palettes have to be removed.

• The hydraulic aggregate has to be activated.

• The hand levers have to be set to the setting store.

• Start the adjustment process by using the RESET button.

• Possibly existing palettes have to be removed.

• Use the AUTOMATIC ON button to activate the station’s automatic mode.

5.5.7. Adjust transport system

• The transport system does not require a special adjustment mode.

• Before start-up by COSIMIR CONTROL, the work-piece carriers are to be positioned onto the transport system, as described in the introduction of this chapter.

• No work-pieces have to be positioned in the work-piece receptions.

• The start of the transport system is carried out by the hydraulic station.

© Festo Didactic GmbH & Co.KG • FMS100

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Commissioning

28

Danger of collision. The linear axis of the CNC station moves to the commission table.

Danger of collision. The arms of the robot have to be removed from any danger area of the CNC machine.

• Before starting the adjustment process, work-pieces remaining in the testing station or in the vice of the processing machine have to be removed.

• If power is available, turn the emergency key switch on the operation panel to position 1 and back to position 0. The emergency circuit is confirmed.

• Start up CNC-machines: switch on both PC´s

Turn key switches of both machines to position 1 and FMS-Mode

• Start the adjustment process by using the RESET button.

• Use the START button to activate the station’s automatic mode.

Danger of collision. In case the robot is very close to or in immediate danger of collision, the robot (robot-arm) is to be removed manually from the danger area.

• Possibly existing palettes and work-pieces have to be removed.

• Activate the controller of the vision system.

• Start the adjustment process by using the RESET button.

• To set the station to automatic mode activate AUTOMATIC ON button.

5.5.10. Start up cell control and COSIMIR CONTROL

• Start up cell control.

• Double click COSIMIR CONTROL icon

• Once the COSIMIR CONTROL picture display appears, a project can be chosen.

• Under “File” you can choose the project

C:\ProgramFiles\COSIMIRCONTROL\Projects\Marmara\Marmara.lpj

• Change to production (See chapter START UP COSIMIR CONTROL in this manual)

© Festo Didactic GmbH & Co.KG • FMS 100

Commissioning

5.6. Shut down the system

5.5.11. Start-up of processes

At this point all of the stations are in automatic mode and fully operational. Existing or newly created processes can be started by means of the cell control.

The creation of processes is described in detail in the station’s manual.

To shut down the system its necessary to proceed as follows:

• Stop production of COSIMIR CONTROL

• Shut down COSIMIR CONTROL software

• Shut down windows and switch of PC. (press power button min. 3 sec.)

• Shut down the CNC-software at the CNC-machines with ALT + F4

• Shut down windows

• Switch off main switch CNC-machines

• Switch off Mitsubishi Drive Units

• Press EMERGENCY button at all other stations

• Switch off all main switches

• Switch off all distribution stripes

© Festo Didactic GmbH & Co.KG • FMS100

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Commissioning

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© Festo Didactic GmbH & Co.KG • FMS 100

6. Operation

notes

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

The stations require some rules of operation witch should be observed. If they are not complied, faults in the processes are possible. Dangers for the physical health also cannot be excluded.

It is recommended to observe the following rules strictly.

• During the operation of the stations it is forbidden to grip in by hand.

• With larger audience a mechanical protection of the stations is necessary.

• Removing any cable under tension is forbidden.

• Water has to be kept away from the plant.

• The stations only may be used by introduced persons.

• The operation has to be carried out according to the operating instructions.

• A pushing the different switches/push buttons of all control units uncheckedly has to be stopped.

• No workpiece carriers may be taken by the system.

© Festo Didactic GmbH & Co.KG • FMS 100

31

Operation

Process description inside AS-RS station.

• If the workcell computer triggers a task – such as the produce a lower housing – the task is passed to the stock computer.

• The palette with the ordered housing is selected and the transport unit moves to the respective shelf.

• The transport unit retrieves the pallet and carry it to the working position on the transport system, where it is placed on the waiting workpiece carrier.

• If the processed housing is returned and storage has been requested, the transport unit collects the palette from the workpiece carrier and stores it in a free shelf.

• The COSIMIR CONTROL computer maintains an overview of the assignment of storage locations and is always aware of the contents of palettes and their locations.

32

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

6.2.2. General

The task of the FMS system is to produce an electrical handheld device. The installation has been designed for three different types of handheld devices. But only type 1 – Roulette is being integrated and programmed in an instant.

The production of a Roulette can be realised by the application of various subprocesses. The following example describes a complete assembly process of a handheld device.

• A palette, containing two raw lower housing parts, is retrieved from the AS/RS station and transported to the CNC station, where the basic bodies are processed inside the CNC milling machine, one after another.

• The processed work-pieces are returned to the AS/RS station for further use.

• The processing of the upper housing parts is identical to that of the lower parts, but processing of the pins ensues in the CNC turning machine.

• The printed circuit boards receive soldering before their assembly. In the soldering station, they are equipped with a battery clip, which is soldered on by a soldering robot. At this point, all of the required components are available.

• The palettes, containing the components, are retrieved from the AS/RS station and transferred to the assembly station, where a lower housing part is placed into the assembly device. The printed circuit board is inserted into the lower part.

A battery is retrieved from the battery magazine and inserted into the battery clip of the printed circuit board. Now, the upper housing part is placed onto the lower part. The housing parts are fixed to another by means of the pressing pins, inserted in the end.

• Once both of the handheld devices are assembled, they are transported to the hydraulic station to receive pressing, one after the other.

• At this point, the handheld device is completely assembled and stored in the

AS/RS station for commissioning.

© Festo Didactic GmbH & Co.KG • FMS100

33

Operation

34

AS/RS 40

PLC – COSIMIR

CONTROL

Station

Ordernumber/

Orderdescription

16 # 1100

Move pallet

Type / Parameter

Parameter 1

Source position

Parameter 2

Target position

Parameter 3 Type

Return code

Nr. Description Available

……

……

Shelf 6 – Shelf 44

Shelf 6 – Shelf 44

1

2

No palette at source position

Target position occupied

3

Telescope not in middle position

15 Timeout

65535 Invalid input parameters

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

The AS-RS station is controlled by means of the operation panel shown below, which is located at the right side of the switchgear cabinet. There are different arrangements of the operation panel, so it is possible that the picture is different to your system.

Operation panel

Start

H6

Flashing

Lights up

Request press „start“

Automatic active

Reset

Special function

Communication on

Auto/Step

Stop

Quitt

Emergency stop

S10

S3

H2

S2

H8

S9

Flashing

Lights up

S8

H7

S7

Start reference move

Special function

Confirm special function

Not used

H9

Choose mode

Position Auto

Position step

Stop automatic at cycle end

Switch on controller

Announce controller off

Switch controller off

Request reset

Reference move ready

Announce special function

Automatic mode

Teach/manual mode

© Festo Didactic GmbH & Co.KG • FMS100

35

Operation

The following actions can be executed from the control strip:

• EMERGENCY STOP

• ACK, acknowledges the EMERGENCY STOP pushbutton.

The system is supplied with 24V.

• SETUP – carries out reference travel.

• START – sets the system to AUTOMATIC mode.

• STOP – system quits AUTOMATIC mode at end of cycle.

• AUTO/MAN, no function

• COMMUNICATION, no function

36

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

The first start-up of the station is to be completed before the station can be adjusted. Retrieve partly processed work-pieces, if required. Clear palette places for the transport system. Electrical current and air are to be available. All of the emergency-off switches are to be unlocked.

CAUTION: Telescope motion – DANGER OF INJURY.

• When the EMERGENCY STOP pushbutton has been acknowledged, the RESET lamp flashes.

• If the RESET pushbutton is pressed, the Y axis and then the X and Z axes carry out reference travel.

• When reference travel has been carried out for each axis the RESET lamp lights and the START lamp flashes.

6.6.1. Start automatic mode

Once it has been successfully reset, the station is ready for the start signal to activate automatic mode. This is indicated by the start button flashing (prompt for entry). The Reset lamp lights.

• When reference travel has been completed, the RESET lamp lights and the START lamp flashes. AUTOMATIC mode can now be started by pressing the AUTOMATIC

ON pushbutton.

• In AUTOMATIC mode, the AS/RS controller can be addressed directly entry into the stock computer or by entry into the workcell computer. Details of operation are given in the appropriate chapters.

6.6.2. Stop automatic mode

• Press the STOP pushbutton.

• The processes currently running are completed to the end of the cycle.

• The START light flashes until the end of the cycle.

• After the end of the cycle, AUTOMATIC mode is off and the status is as in

Activating automatic mode and starting the process.

© Festo Didactic GmbH & Co.KG • FMS100

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Operation

Teach Box AS-RS

38

In TEACH mode, the telescope can be moved precisely to the various positions and these positions can be stored.

CAUTION: Telescope motion – DANGER OF INJURY.

• To enter TEACH mode press and hold the TEACH pushbutton during power-up

(acknowledge EMERGENCY STOP). The TEACH pushbutton can be released when the STATUS lamp begins to light. The systems carries out reference travel and the

STATUS lamp begins to flash.

• When reference travel is finished (STATUS lamp on) the transport system unit travels to Position 1 and teaching of positions can begin.

Teach Box

AS-RS

TEACH STATUS

POS-NR.

ENTER

INCR.

TELESKOP

IN/OUT

MOVE TO

POSITION

1

2

AXIS

3

4

JOG

-

+

1 X-AXIS

2 TELESKOP

3 Z-AXIS

4 NOT ACTIVE

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

TEACH

ENTER

INCR.

TELESCOPE IN/OUT

MOVE TO POSITION

ROTARY SWITCH

Pressed

Pressed

Pressed

Starts TEACH mode when pressed and held during power-up.

Store current position values to the selected position number.

Rotary switch in position 1 / 2

Rotary switch in position 3 / 4

Switch to bottom position

Select position increment

Select position decrement

Transport system unit travels to teach position.

1

2

3

Switch to top position

Pressed

Transport system unit travels to mid position.

Move to selected position

1. Transport system unit moves to mid position.

2. X and Z axis move to preselected positions.

3. Transport system unit moves to stored Teach position.

Move X axis

Move telescope

Move Z axis

Pos. no.

AXIS

Status

1-40

90

95

Storage locations are labeled with pos. numbers.

Transport system position to conveyor system

Telescope mid position (not teachable)

41-89

91

Not activated by program

Storage position / Manual

92 Retrieve position / Manual

93/94 Reserve

2 Telescope

5-9

Flashing

Steady

Not activated by program

Reference travel in progress

Reference travel complete

© Festo Didactic GmbH & Co.KG • FMS100

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Operation

Switch Telescope Position

JOG+

JOG-

Mid position

Extended

Mid position

Extended

Pressed briefly

Pressed and held

Pressed briefly

Pressed and held

Pressed briefly

Pressed and held

Pressed briefly

Pressed and held

Function

The selected axis (X, Y or Z axis) moves 100 increments in positive direction per press.

The selected axis (X, Y or Z axis) moves with increasing speed in positive direction.

The selected axis (X or Y axis) moves 100 increments in positive direction per press. The Z axis carries out absolute motion to lift out the pallet.

The selected axis (X or Y axis) moves with increasing speed in positive direction The Z axis carries out absolute motion to lift out the pallet.

The selected axis (X, Y or Z axis) moves 100 increments in negative direction per press.

The selected axis (X, Y or Z axis) moves at increasing speed in negative direction.

The selected axis (X or Y axis) moves 100 increments in negative direction per press. The Z axis carries out absolute motion to set down the pallet.

The selected axis (X or Y axis) moves at increasing speed in negative direction. The Z axis carries out absolute motion to set down the pallet.

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© Festo Didactic GmbH & Co.KG • FMS 100

Operation

6.7.1. Example teach a position

TEACH mode is only suitable for teaching storage locations.

If the preteach positions are no longer present (e.g. new CPU), the basic positions (if necessary, the complete project), must be reloaded. The positions are located as follows:

Controller axis file

S7

IPC All axis File 10

If the system is in TEACH mode and reference travel has been completed, teaching of positions (e.g. Position 1 (storage location 1) can begin.

1. To prevent collisions during traverse of axes, all sources of danger – such as pallets in the storage location to be entered – must be removed.

2. Position 1 is selected with the INCR pushbutton. (Each press increments the position number by 1, only increment is possible.) Pressing MOVE TO POSITION causes motion to the position. The Y axis is extended and the Z axis is in its bottom position.

3. The X axis is selected by switching the rotary switch to position 1. JOG+ and

JOG- allow repositioning on the X axis.

4. The Y axis can now be selected by turning the rotary switch to position 2. JOG+ and JOG- allow teaching in the Y axis.

5. As the Y axis is extended, the motion in the Z axis can only be absolute, that is, the path necessary to lift out the pallet.

6. If teaching of the Z axis is necessary, the telescope must be brought into mid position with the aid of the TELESCOPE IN/OUT pushbutton.

7. JOG+ and JOG- can now be used to teach the Telescope mid position in the Z axis.

8. When the final position has been reached, the selected position can be stored by pressing the ENTER pushbutton.

9. Pay Attention only for IPC: If you write the value from a position into a flag word with pressing the ENTER –pushbutton, all positions are stored into file 10.

© Festo Didactic GmbH & Co.KG • FMS100

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Operation

IPC

S7-300

Move to position

Quit teach mode

6.7.2. Load positions into controller

2. Start the program execution in the utilities menu

3. Choose file operations

4. The connection to the controller is setup (could need a little time)

5. With the function-key F2 choose

6. From PC to load file on IPC

7. From IPC to load file to PC

8. Choose file 10

9. Choose destination drive ( A:\ ) with function-key F7

10. Load file into the controller with function-key F1

1. Start simatic manager

3. Open controller online

4. Open module-reservoir in online and offline window

5. DB 10; DB 11,DB 12 from

6. Copy from offline window to online window (Data module is transmits into controller)

7. Copy from online window to offline window (Data module is transmitted from controller)

1. If the system is in an arbitrary position (such as position 2), Position 1 can be selected with the aid of the INCR pushbutton.

2. The INCR pushbutton is pressed until Position 1 is displayed in the POS display

(only increment is possible).

3. Press the MOVE TO POSITION pushbutton. The system moves to the position stored in Position 1.

4. In this way, the system can be moved to any stored position.

This mode can be left only by de-activation of the supply voltage or actuation of the

EMERGENCY OFF.

42

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

AS/RS Manager

The following project serves as an example. The operation for other projects is the same. It is also the same operation for AS/RS with 48 shelves.

Change to AS/RS Manager

The AS/RS-Manager is started automatically while starting COSIMIR CONTROL. To change into the AS/RS-Manger menu click on STOCK ADMINISTRATION button on the windows task bar.

AS/RS-Manager

© Festo Didactic GmbH & Co.KG • FMS100

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Operation

Move in AS/RS-Manager

Move one shelf backwards

Move one shelf forwards

Move to shelf 1 Move to shelf 40

Black frame/active shelf

To choose a shelf it is possible to click directly onto the shelf, or move with the buttons to the chosen shelf.

If a AGV is integrated in the system, shelf 13 is reserved for pallet handling. The reserved shelf 13 is marked with a blue frame like in the picture below.

44

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

Modify parts

Click on chosen part – part is shown in detail shelf view. To edit a zone number, it is the same procedure.

Click on modify button to get into shelf edit mode.

© Festo Didactic GmbH & Co.KG • FMS100

45

Operation

Part ready for changes

Change partnumber

Click onto partnumber and change partnumber manually

Activate new settings

Click on update to take over the new settings

New settings

New settings are active.

46

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

Reserve part

Reserved shelf

Click on MODIFY button, click on RESERVED field, insert 1 and click on update to activate the settings.

The key is the sign for a reserved shelf. Now it is not possible to retrieve or move the pallet of this shelf. If the shelf would be empty, it is not possible to store something in this shelf.

© Festo Didactic GmbH & Co.KG • FMS100

47

Operation

6.8.2. Retrieve function / Search for part number

Click on RETRIEVE button to activate retrieve mode. Activate SEARCH FOR PART

NUMBER / the first shelf witch is occupied with the chosen part number will give over the pallet.

Retrieve part 60 244

To retrieve a part, insert the chosen part number in field PART NO. ORDER NO. is always 0. Click on START button.

48

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

Retrieve order active

Chosen part is reserved for retrieve.

Part is retrieved

Part is retrieved, shelf 12 is empty

© Festo Didactic GmbH & Co.KG • FMS100

49

Operation

6.8.3. Retrieve function / retrieve shelf direct

Click on RETRIEVE button to activate retrieve mode. Activate RETRIEVE SHELF DIRECT

/ Choose shelf, insert number in field SHELF NO.

Retrieve shelf 10

To retrieve a part, insert the chosen shelf number in field SHELF NO. Click on START button.

Retrieve order active

50

Chosen shelf is reserved for retrieve.

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

Part is retrieved

Part is retrieved, shelf 10 is empty

© Festo Didactic GmbH & Co.KG • FMS100

51

Operation

Open product list

6.8.4. Zoning

It is possible to devide the stock in different zones. So it is possible to store different parts in different zones of the stock. For example all black parts are in zone 1 (shelf 1 to 8), all red parts are in zone 2 (shelf 9 to 16). In the main screen of the AS/RS-

Manager, in edit mode, it is possible to edit the shelves and give them a zone number (see chapter modify function). The parts are edited in the product list.

If the ENABLE ZONING button in store mode is active, the parts need a zone number.

In this case it is only possible to store the parts in the respective zone of the stock, if the zone numbers of the part and of the shelf are identical.

Click on PRODUCT LIST button to edit parts for zoning.

Edit part

New settings

52

Click on chosen part in product list. Change zone number in edit field, for example to

5. Click on UPDATE button to activate the new settings.

The new settings are active. Now part number 60 245 can only be stored in zone 5 of the stock.

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

6.8.5. Store function / search for empty shelf

In store mode SEARCH FOR EMPTY SHELF there is an order ENABLE ZONING: it is possible to distribute the stock in different zones. If the ENABLE ZONING button is active, the parts need a zone number and it is only possible to store them in the respective zone of the stock. See chapter zoning. If the button is inactive, the parts are stored in the first empty shelf.

Click on STORE button to activate store mode. Activate SEARCH FOR EMPTY SHELF and ENABLE ZONING.

Store part no 60245

To store a part, insert the chosen part number in field PART NO. The ORDER NO. is always 0. Click on the START button. The part will be stored in the first empty shelf.

© Festo Didactic GmbH & Co.KG • FMS100

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Operation

Store order active

Shelf 7 is reserved to store part no. 60 245. It is the first empty shelf in stock.

Part 60 245 is stored

Part is stored in the first empty shelf.

54

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

Store part no 60245

6.8.6. Store function / store shelf direct

Click on STORE button to activate store mode. Activate STORE SHELF DIRECT.

To store a part, insert the chosen part number in field PART NO. The ORDER NO. is always 0, insert the chosen SHELF NO (Take care that the shelf is empty). Click on the START button.

© Festo Didactic GmbH & Co.KG • FMS100

55

Operation

Store order active

Shelf no.12 is reserved to store part no. 60 245.

Part 60 245 is stored

Part is stored in shelf no. 12

56

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

Click on the MOVE button to activate move mode.

Move part no 62 101 from shelf 27 to shelf 14

To move a part, insert the actual shelf number of the chosen part in field SOURCE

SHELF, insert the number of the destination shelf into DESTINATION SHELF field.

Click on START button.

Move order active

Shelf number 27 and 14 are reserved to move part number 62 101.

© Festo Didactic GmbH & Co.KG • FMS100

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Operation

Part 62 101 is moved

Part number 62 101 is moved from shelf 27 to shelf no. 14

58

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

6.8.8. First time init

To get initial conditions the button FIRST TIME INIT has to be activated. If the function is executed, the stock is in original conditions. These conditions depend on the project.

Start first time init

Confirm window

Click on FIRST-TIME-INIT button to start the first time initial mode.

Confirm with yes and OK button to start first time init.

© Festo Didactic GmbH & Co.KG • FMS100

59

Operation

New conditions

New conditions are active, Click on OK to continue.

60

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

Product classes

Open product list

6.8.9. Edit Product list

It is possible to edit available parts or to insert new parts in product list.

No parts

No processed parts

Processed covers

Processed cylinders

Palette for clinders

Palette for Covers

Change to product list.

Click on button PRODUCT LIST button to edit parts.

Edit part

New settings

Click on chosen part in product list. Change settings in edit field, for example change zone number from 1 to 5. Click on UPDATE button to activate the new settings.

The new settings are active. Part number 60 245 is configured for zone 5.

© Festo Didactic GmbH & Co.KG • FMS100

61

Operation

Create new part

Edit settings for new part

To create a new part, click on NEW button.

Insert settings for new part in edit field.

Save settings

Save settings for new part. Click on SAVE button.

62

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

New product is active

The new product is active.

Delete part

To delete a part, activate the part and click on DELETE button.

© Festo Didactic GmbH & Co.KG • FMS100

63

Operation

6.8.10. Trouble shooting / AS-RS-Manager

RETRIEVE mode / SEARCH FOR PART NUMBER

No entry found in database

Confirm message

No entry found in database - There is no part with the chosen part number in the stock.

Confirm message and insert new part number.

64

© Festo Didactic GmbH & Co.KG • FMS 100

Operation

6.8.11. RETRIEVE mode / RETRIEVE SHELF DIRECT

No part available

No part available in selected source shelf - There is no part in chosen shelf. Confirm message and insert new shelf number.

Wrong zoning number

The zoning number is wrong, edit zoning number from shelf or part. Confirm message and edit zoning number.

© Festo Didactic GmbH & Co.KG • FMS100

65

Operation

Destination shelf occupied

Move order, destination shelf already occupied, confirm message, edit destination shelf. Take care that destination shelf is free.

Wrong partnumber

66

The part number is wrong, there is no part with this number in product list. Confirm message, insert new part number or edit product list and create a new part.

© Festo Didactic GmbH & Co.KG • FMS 100

7. Technology

7.1. drawings

This chapter refers to the technology of the AS-RS station.

For better construction understanding of the station, the technical drawings should be a very helpful data.

The rooms must be checked for their technical datas before built up the station/system. The size of the door openings and the entrance must be big enough for the measurements of the system. Even the load-capacity of the floor must be high enough for the system.

Technical drawing AS-RS station

© Festo Didactic GmbH & Co.KG • FMS 100

67

Technology

7.2. Modules in use

The AS-RS station is made up of a number of different function modules.

• Palette reception

• Telescope

On this module the palettes are stored in the AS-RS

Example palette reception

Performance

Inputs /

Outputs /

Max. reservation 48 palette receptions

68

© Festo Didactic GmbH & Co.KG • FMS 100

Technology

Position of all shelves

• Position 90: Transport system position at the conveyor system

• Position 95: Telescope mid position

Transport direction

© Festo Didactic GmbH & Co.KG • FMS100

69

Technology

70

Shelf number

18

19

20

21

14

15

16

17

22

23

24

10

11

12

13

6

7

8

9

3

4

5

1

2

Part number

60430

60430

60430

60430

60430

60470

60470

60470

60470

60470

60470

60410

60411

60411

60411

60411

60411

60411

60430

60410

60410

60410

60410

60410

7.2.2. First time list

This allocation of the AS/RS station fulfills the basic conditions to ensure the operation of the installation. This storage allocation is to be established with each production start-up.

Designation

2 x Raw lower housing part

2 x Raw lower housing part

2 x Raw lower housing part

2 x Raw lower housing part

2 x Raw lower housing part

2 x Raw lower housing part

2 x Raw upper housing part

2 x Raw upper housing part

2 x Raw upper housing part

2 x Raw upper housing part

2 x Raw upper housing part

2 x Raw upper housing part

8 x Raw pins on palette

8 x Raw pins on palette

8 x Raw pins on palette

8 x Raw pins on palette

8 x Raw pins on palette

8 x Raw pins on palette

2 x PCB type 1 / Roulette not soldered

2 x PCB type 1 / Roulette not soldered

2 x PCB type 1 / Roulette not soldered

2 x PCB type 1 / Roulette not soldered

2 x PCB type 1 / Roulette not soldered

2 x PCB type 1 / Roulette not soldered

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

6

Number units

© Festo Didactic GmbH & Co.KG • FMS 100

Technology

42

46

47

48

43

44

45

30

34

35

36

37

31

32

33

38

39

40

41

25

26

27

28

Shelf number

Part number

60412

60412

60412

60413

29

60413

60413

60472

60472

60472

60431

60431

60431

60471

60471

60471

60471

60401

60401

62400

62400

62400

62400

62400

62400

Designation

2 x Processed lower housing part

2 x Processed lower housing part

2 x Processed lower housing part

2 x Processed upper housing part type 1 /

Roulette

2 x Processed upper housing part type 1 /

Roulette

2 x Processed upper housing part type 1 /

Roulette

2 x PCB type 1 / Roulette soldered tested

2 x PCB type 1 / Roulette soldered tested

2 x PCB type 1 / Roulette soldered tested

8 x Processed pins on palette

8 x Processed pins on palette

8 x Processed pins on palette

2 x PCB type 1 / Roulette soldered not tested

2 x PCB type 1 / Roulette soldered not tested

2 x PCB type 1 / Roulette soldered not tested

2 x PCB type 1 / Roulette soldered not tested

2 x Handheld device type 1 / Roulette mounted not fixed

2 x Handheld device type 1 / Roulette mounted not fixed

Palette 2ED (for 2 electrical handheld devices)

Palette 2ED (for 2 electrical handheld devices)

Palette 2ED (for 2 electrical handheld devices)

Palette 2ED (for 2 electrical handheld devices)

Palette 2ED (for 2 electrical handheld devices)

Palette 2ED (for 2 electrical handheld devices)

3

3

3

Number units

3

3

3

3

3

3

4

3

3

3

4

4

4

2

2

6

6

6

6

6

6

© Festo Didactic GmbH & Co.KG • FMS100

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Technology

7.2.3. Telescope

The pallets will submit with the help of the telescope from the transport system to the AS-RS - or the other way. The telescope can extend on the two sides, it can drive over the conveyor belt and it can drive over a pallet reception.

Telscope

Performance

Max. reservation 1 piece

72

© Festo Didactic GmbH & Co.KG • FMS 100

Technology

Pos.

3

4

5

1

2

6

7

Designation / Criterion

Width:

Max. width

Length

Max. length height

Max. height

Weight

Measurements / Feature

1 000 mm

1 300 mm

2 380 mm

2 380 mm

1 790 mm

1 810 mm approx. 420 kg

© Festo Didactic GmbH & Co.KG • FMS100

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Technology

74

Handling unit drive

x-axis

8

9

1

4

5

6

7

1

2

3

4

5

6

7

1 Drive type

2 Type

3 Traversing range

Safety limit switch

Safety limit switch

Reference switch

Release switch

Motor data

Type

Rated voltage

Rated speed

Rated torque

Starting torque

Rated current

Demagnetising current

No-load current

Resolution

Gearing data

Gear ratio

3

4

5

2 Rated torque

Incremental encoder

1 Resolution

23 mm / incr.

Channels

1mm move

1 motor turn

Hardware

Software

Software

Software

Toothed belt

DGEL-40-1400-ZR-KF-GK-LK-RV-KG

1 400 mm

2 x roller levers

1 x SME-8; electric switch

1 x SME-8; electric switch

1 x SME-8; electric switch

GR 53 x 58

24 V

3000 r.p.m.

17.0 Ncm

140.0 Ncm

2.9 A

31.0 A

0.2 A

10 125 incr./rev.

20,25 : 1

344.25 Ncm

0.0098765 mm / incr.

A / B / Index

101,25 incr.

2,7391 mm

© Festo Didactic GmbH & Co.KG • FMS 100

Technology

Handling unit drive

y-axis

6

7

8

9

1

2

3

4

5

1 Drive type

2 Type

3 Traversing range

4 Reserve switch

5 Reference switch

Motor data

1 Type

Rated voltage

Rated speed

Rated torque

Starting torque

Rated current

Demagnetising current

No-load current

Resolution

Gearing data

Gear ratio

4

5

2

3

2 Rated torque

Incremental encoder

1 Resolution mm / incr.

Channels

1 mm move

1 motor turn

Software

Software

Toothed belt

390 mm

1x SOEG-L; optic switch

1 x SME-8; electric switch

24 V

3030 r.p.m.

3.0 Ncm

12.1 Ncm

0.71 A

12.1 A

0.13 A

81000 incr./ rev.

162 : 1

486 Ncm

0.0011312 mm / incr.

A / B / Index

883,992 incr.

1,768 mm

© Festo Didactic GmbH & Co.KG • FMS100

75

Technology

76

Handling unit drive

z-axis

4

5

5

1 Drive type

2 Type

3 Traversing range

Safety limit switch

Reserve switch

Reference switch

Motor data

9

1

2

5

6

7

8

3

4

1 Type

2 Rated voltage

Rated speed

Rated torque

Starting torque

Rated current

Demagnetising current

No-load current

Resolution

Gearing data

Gear ratio

Rated torque

3

4

5

Incremental encoder

1 Resolution

2 mm / incr.

Channels

1 mm move

1 motor turn

Hardware

Software

Software

Toothed belt

DGEL-25-1000-ZR-KF-GK

1 000 mm

2 x roller levers

1 x SME-8; electric switch

1 x SME-8; electric switch

24 V

3600 r.p.m.

10.0 Ncm

67.0 Ncm

2.3 A

20.0 A

0.28 A

16 000 incr./ rev.

32 : 1

320 Ncm

0.0039375 mm / incr.

A / B / Index

253,9683 incr.

2,7391 mm

© Festo Didactic GmbH & Co.KG • FMS 100

8. Electrical system

To operate the station it is required to connect all of the supply cables and communication lines included. The cables used to program the system are explained additionally.

To give you a better survey of the being lines used in the plant, these are explained in the following.

The devices are delivered together with the respective power supply plugs, protectively contact covered, in case they require power supply.

The customer must ensure that the power supply is earthed correctly and is equipped with a fault current monitor.

If it is required for several devices to be in operation at the same time, it is possible to connect these to a switchboard containing distribution board, provided that the permissible maximum rating is not exceeded.

Each station contains its own individual EMERGENCY STOP switch, which at first reacts to its respective station only. It has to be clarified in advance, if a central

ROOM EMERGENCY STOP switch is required.

© Festo Didactic GmbH & Co.KG • FMS 100

77

Electrical system

8.2. Controller 8.2.1. Controller design IPC

No. Switch Name

1

2 -

6

7

8

3

4

5

-

4

1

2

1

2

3

Power supply

Profibus card

Servo card

Servo card

I/O-card

I/O-card

I/O-card

PS 10

CP 60

AM 20

AM 20

OM 21

OM 21

OM 21

Comment

For external communication

For x and z-axle

For y-axle

For operation

For I/O-coupling

For transport system unit

IPC controller AS-RS station

The communication ensues by means of Profibus, should the station be connected to another station, as described under the point complete process, for example.

The IPC in the AS/RS switchgear cabinet is programmed from the computer via the serial cable (RS232 cable). The serial-cable is plugged into the

RS 232 interface on the programming computer and is connected directly to the IPC-

Controller (HC 16 com 1).

78

© Festo Didactic GmbH & Co.KG • FMS 100

Electrical system

8.3. Wiring

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

8.3.1. I/O-Components

The operation panel, the modules from station are pluggable connected via

I/O-terminals to the I/O-cards from the control.

So that a perfect communication can be ensured, the I/O interface is standardised.

The I/O terminal is at all work positions at the disposal.

I/O-Terminal

Technical data

Plug type IEEE 488 24 pins

Inputs 8

Outputs 8

Current consumption

Power supply

Max. 1A/PIN

24 VDC

© Festo Didactic GmbH & Co.KG • FMS100

79

Electrical system

Allocation I/O- Terminal

OUT BIT 0

OUT BIT 1

OUT BIT 2

OUT BIT 3

OUT BIT 4

OUT BIT 5

OUT BIT 6

OUT BIT 7

POWER 24 VDC

POWER 24 VDC

POWER 0 VDC

POWER 0 VDC

8

9

6

7

3

4

1

2

5

10

11

12

17

18

19

20

21

22

23

24

13

14

15

16

IN BIT 0

IN BIT 1

IN BIT 2

IN BIT 3

IN BIT 4

IN BIT 5

IN BIT 6

IN BIT 7

POWER 24 VDC

POWER 24 VDC

POWER 0 VDC

POWER 0 VDC

syslink pin assignment

01 Bit 0 Output word white

02 Bit 1 Output word brown

03 Bit 2 Output word green

04 Bit 3 Output word yellow

05 Bit 4 Output word grey

06 Bit 5 Output word pink

07 Bit 6 Output word blue

08 Bit 7 Output word red

09 24 V Power supply black

10

11 0 V Power supply pink-brown

12 0 V Power supply purple

13 Bit 0 Input word grey-pink

14 Bit 1 Input word red-blue

15 Bit 2 Input word white-green

16 Bit 3 Input word brown-green

17 Bit 4 Input word white-yellow

18 Bit 5 Input word yellow-brown

19 Bit 6 Input word white-grey

20 Bit 7 Input word grey-brown

21 24 V Power supply white-pink

22

23 0 V Power supply white-blue

24

80

Clamp Bit Function Color

01 0 Output White

02 1 Output Brown

03 2 Output

04 3 Output

Green

Yellow

05 4 Output

06 5 Output

07 6 Output

08 7 Output

09

Grey

Pink

Blue

Red

10

11

Clamp Bit Function Colour

13 0 Input Grey-pink

14 1 Input Red-blue

15 2 Input White-green

16 3 Input Brown-green

17 4 Input White-yellow

18 5 Input Yellow-brown

19 6 Input White-grey

20 7 Input Grey-brown

21 24V

Power supply

22

White-pink

24

White-blue

© Festo Didactic GmbH & Co.KG • FMS 100

9. Trouble-shooting

To be able to produce the operation of the system at a fault as fast as possible again, this fault list is imaginary.

A fault/problem is shown by a fast blinking special function lamp.

Reset move is not getting ready because servo-axis doesn’t move anymore.

Servo-axis doesn’t move anymore.

Mechanical collision with telescope

Adjust Mattke – controller for servo-axis (s.o. data sheets)

Adjust Mattke – controller for servo-axis (s.o. data sheets)

Move axis by hand - The axles are to be moved very slowly only, otherwise voltage induction may occur.

Adjust sensor B10.4 middle position of telescope Telescope doesn’t move anymore

© Festo Didactic GmbH & Co.KG • FMS 100

81

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