iCIM FC Robot RV2AJ Assembly Vision A008

iCIM

Manual

Robot assembly vision station

2 © Festo Didactic GmbH & Co.KG. • iCIM

Order-NR.:

Type: Manual iCIM

Designation iCIM_FC_Robot_RV2AJ_Assembly_Vision_A008.doc

Printed: November 08

Autor: Schober

Graphics: Schober

Layout: Schober

© Festo Didactic GmbH & Co.KG., D-73770 Denkendorf, 2008

Internet: www.festo.com/didactic

e-mail: [email protected]

This manual, all text and illustrations included, is protected by copyright. Any utilization 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 authorized

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. • iCIM 3

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

This installation was developed and manufactured only for use in basic and further training in the fields of automation and communications. The training company and/or the training staff must ensure that the trainees observe the safety precautions described in the accompanying manuals. Furthermore this manual describes setup and possible uses of the singular stations. It contains all information and data required for commissioning, maintenance and operation.

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

The manual is divided into four parts:

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

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

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

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

1 Intended use


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

• DIN EN 292 -Machine safety • DIN EN 60204 - Electrical equipment of industrial machines • DIN VDE 0113 - See DIN EN 60204 • DIN 40719 - Circuit documentation • VDI 2853 - Technical safety requirements concerning the building, equipping and

operation of industrial robots • VDI 2853 - Technical safety requirements concerning automated production

systems • VDI 2411 - Terms and explanations in conveying and handling • VDI 2860 - Assembly and robotics - terms • VDI 2861 - Assembly and robotics - characteristic quantities • DIN 19245 - PROFIBUS Part 1-3

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

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

+49(711-3467-0)

List of applicable standards and regulations


Contents

1 Intended use _____________________________________________________ 3

2 Introduction ______________________________________________________ 9

2.1 General ______________________________________________________ 9

2.2 Robot assembly station _______________________________________ 10

2.3 Didactic structure ____________________________________________ 12

2.4 Duty of the operating authority _________________________________ 13

2.5 Duty of trainees ______________________________________________ 13

2.6 Warranty and liability _________________________________________ 14

2.7 Intended use ________________________________________________ 14

2.8 Important notes ______________________________________________ 15

3 General safety instructions _________________________________________ 17

3.1 Handling the system __________________________________________ 17

3.1.1 Dangers in handling the machine ____________________________ 17

3.1.2 Faults impairing safety must be rectified immediately! ___________ 17

3.1.3 Safety precautions in standard operation _____________________ 18

3.1.4 Dangers due to electric current _____________________________ 18

3.1.5 Dangers due to pneumatic energy ___________________________ 19

3.1.6 Maintenance – Servicing – Malfunction removal ________________ 19

3.1.7 Organizational measures __________________________________ 19

3.2 Personnel ___________________________________________________ 20

3.2.1 Notes on personnel _______________________________________ 20

Contents


3.2.2 Training operations _______________________________________ 20

3.2.3 Outside training operations ________________________________ 20

3.3 Emergency stop system _______________________________________ 20

3.3.1 Safety symbols __________________________________________ 21

4 Commissioning __________________________________________________ 23

4.1 Transport ___________________________________________________ 23

4.1.1 Unpacking ______________________________________________ 23

4.1.2 Scope of delivery _________________________________________ 23

4.2 Set up ______________________________________________________ 24

4.2.1 General information ______________________________________ 24

4.3 Commissioning ______________________________________________ 28

4.3.1 Pneumatic commissioning _________________________________ 28

4.3.2 Electric commissioning ____________________________________ 28

4.3.3 Connecting communication cables ___________________________ 29

4.3.4 Establishing communication connections _____________________ 30

5 Operation _______________________________________________________ 31

5.1 General operation notes _______________________________________ 31

5.1.1 Behavior rules ___________________________________________ 31

5.1.2 Operation rules __________________________________________ 31

5.2 Process description ___________________________________________ 32

5.2.1 Robot assembly station ___________________________________ 32

5.3 Tasks ______________________________________________________ 33

Contents


5.4 Operation panel ______________________________________________ 37

5.5 Start up system ______________________________________________ 38

5.5.1 Start up conditions _______________________________________ 38

5.5.2 general information _______________________________________ 38

5.6 Reset mode _________________________________________________ 38

5.7 Automatic __________________________________________________ 39

5.7.1 Start automatic __________________________________________ 39

5.7.2 Automatic mode _________________________________________ 39

5.7.3 Stop automatic __________________________________________ 39

5.8 Shut down the station _________________________________________ 39

5.9 Mitsubishi robot RV-2AJ _______________________________________ 40

5.10 Drive Unit RV-2AJ _____________________________________________ 41

5.10.1 Functions _______________________________________________ 41

5.10.2 Teach pendant RV-2AJ _____________________________________ 43

5.10.3 Set up RV-2AJ ____________________________________________ 44

5.10.4 To operate the robot ______________________________________ 45

5.10.5 Choose program _________________________________________ 48

5.10.6 Change program _________________________________________ 48

5.10.7 Teach position example ___________________________________ 49

5.10.8 Interface Drive unit Inputs _________________________________ 50

5.10.9 Interface Drive unit Outputs ________________________________ 51

5.10.10 Program documentation for CR1 and CR2 with ETHERNET ______ 52

Contents


5.10.11 Robot programs ________________________________________ 56

6 Technology _____________________________________________________ 59

6.1 drawings ___________________________________________________ 59

6.2 Technical datas ______________________________________________ 60

6.3 Modules in use ______________________________________________ 61

6.3.1 Pallet reception __________________________________________ 61

6.3.2 Pen/instrument magazine _________________________________ 62

6.4 Assembly module ____________________________________________ 63

6.5 Workpiece direction __________________________________________ 64

7 Pneumatic ______________________________________________________ 65

7.1 The valve terminal ____________________________________________ 65

7.2 Pneumatic supply ____________________________________________ 66

8 Electrical system _________________________________________________ 67

8.1 Power supply ________________________________________________ 67

8.2 Controller ___________________________________________________ 67

8.3 Wiring ______________________________________________________ 68

8.3.1 I/O-Components _________________________________________ 68


This user-defined installation contains parts of the iCIM 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 iCIM 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.

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

2 Introduction

2.1 General

Introduction


The robot assembly stationis responsible for the assembly of an desk set in different variants.

Once a desk set is to be assembled, the required palettes, containing the necessary components, are requested for placement onto the palette receptions.

At first, a base plate is placed into the assembly position, then the first instrument is assembled. After assembling the first instrument, the second instrument is assembled in the same way. The instruments are coming from the magazines. 1 pen holder, aluminum or brass, depending on the order, is assembled into the base plate. The pen holder is coming from a palette. At least a pen is inserted in the pen holder, the pen is coming from the magazine. The assembled desk set is returned to its retrieval position and stored in the AS/RS station for further use.

The station possesses its own control, which is fitted into the basic frame of the station. The drive unit of the robot supplies the control.

• Communication from drive unit to COSIMIR FACTORY PC ensues by means of Ethernet

If the station is operated without the iCIM System, in “stand alone” mode, it is possible to make training on the robot.

2.2 Robot assembly station

Introduction


Overview AS/RS station

Position Description Position Description

1 Robot RV-2AJ 7 Camera

2 Controller CR1 8 Pen-magazine

3 RIA-Box 9 Assembly module

4 Operation panel 10 Workpiece holder for vision

5 Magazine 1 11 Palette reception

6 Magazine 2

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.

2.3 Didactic structure

Introduction


Training contents covering the following subjects can be taught:

• Mechanics – Mechanical construction of a station

• Pneumatics – Piping connections of pneumatic components – Vacuum technology – Pneumatic linear and rotary drives

• Electrical – Correct wiring of electrical components

• Sensors – Correct use of limit switches

• Robot training – Programming and use of a Robot – Structure of a robot program – Moving and teaching a robot

• Commissioning – Commissioning of a production system

• Fault finding – Systematic fault finding on a production system

The operating authority undertakes to ensure that the ICIM is used only by persons who:

• are familiar with the basic regulations regarding operational safety and accident prevention and who have received instructions in the handling of the ICIM,

• have read and understood the chapter on safety and the cautionary notes in this manual.

• Safety-conscious working of the persons should be regularly vetted.

Prior to commencing work, all persons assigned to working on the ICIM have a duty to:

• read the chapter on safety and the cautionary notes in this manual and, • observe the basic regulations regarding operational safety and the prevention of

accidents.

2.4 Duty of the operating authority

2.5 Duty of trainees

Introduction


In principle all our „Terms and Conditions of Sale“ apply. These are available to the operating authority upon conclusion of the contract at the latest. Warranty and liability claims for persons or material damage are excluded if these can be traced back to one or several of the following causes:

• Use of the ICIM not in accordance with its intended purpose • Incorrect assembly, commissioning, operation and maintenance of the ICIM • Operation of the ICIM using faulty safety equipment or incorrectly fitted or non

operational safety or protective devices

• Non observance of notes in the manual regarding transport, storage, assembly, commissioning, operation, maintenance and setting up of the ICIM

• Unlawful constructional modifications on the ICIM • Inadequate monitoring of components subject to wear • Incorrectly carried out repairs • Catastrophes as a result of foreign bodies and vis major.

Festo Didactic herewith rules out any liability for damage or injury to trainees, the training company and/or other third parties which may occur during the use/operation of the system other than purely in a training situation, unless such damage has been caused intentionally or due to gross negligence by Festo Didactic.

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 use of the system for its intended purpose also includes:

• Following all advice in the manual and • Carrying out inspection and maintenance work.

2.6 Warranty and liability

2.7 Intended use

Introduction


The basic requirement for safe use and trouble-free operation of the ICIM is to observe the fundamental safety recommendations and regulations.

This manual contains important notes concerning the safe operation of the ICIM.

The safety recommendations in particular must be observed by anyone working on the ICIM.

Furthermore, the rules and regulations for the prevention of accidents applicable to the place of use must be observed.

2.8 Important notes

Introduction



3.1.1 Dangers in handling the machine

The installation has been constructed technologically up to date and in conformance with the recognized 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 cannot be tolerated during training and have to be removed immediately.

The iCIM system is to be used only:

• for its intended purpose and • in an absolutely safe conditions.

3.1.2 Faults impairing safety must be rectified immediately!

3 General safety instructions

3.1 Handling the system

General safety instructions


3.1.3 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.

3.1.4 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.



3.1.5 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.

3.1.6 Maintenance – Servicing – Malfunction removal

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

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

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

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

3.1.7 Organizational measures

All existing safety devices must be checked at regular intervals.



3.2.1 Notes on personnel

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

• Activities during training operations • Activities outside training operations

3.2.2 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.

3.2.3 Outside training operations

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

The emergency stop system is controlled by a higher safety control unit. The description is noted in the manual of the transport system.

3.2 Personnel

3.3 Emergency stop system



3.3.1 Safety symbols

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

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

DANGER !

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

This symbol emphasizes important information for correct machine handling.

IMPORTANT

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

This symbol indicates operational tips and especially useful directions. i

INFORMATION

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




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

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

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

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

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

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

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

Check the station for any possible damaged once unpacked. The carrier and Festo Didactic are to be notified immediately of any damage.

4.1.1 Unpacking

Carefully remove the padding material in the container box when unpacking the station. When unpacking the station, make sure that none of the station assemblies have been damaged.

Check the station for any possible damaged once unpacked. The carrier and Festo Didactic are to be notified immediately of any damage.

4.1.2 Scope of delivery

Check the scope of delivery against the delivery note and the order. Festo Didactic must be notified immediately of any discrepancies.

4 Commissioning

4.1 Transport

i

Commissioning


4.2.1 General information

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

In countries with an atmospheric humidity over 70% and temperatures above 25 degrees Celsius are the premises to provide an air-conditioning system for constant surroundings conditions.

To comply with 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 fault-free 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).

First, the room has to be measured, if not done so previously. The measures of all stations have to be marked roughly onto the floor space (i.e. with adhesive tape) to avoid shifting at a later stage.

If the build up position is fixed, the station has to be mounted at the respective operating position of the transport system, utilizing the included profiles. At this point, screw and lean the profiles lightly onto the basic frame of the transport system station. Align the station by means of a spirit-level and tighten the connector profiles afterwards.

The robot transfer position to the transport system and the positions for the work-piece transfer may require to be retaught.

4.2 Set up

Commissioning


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

For a more simple room planning the complete installation design is shown in the following.

Installation design iCIM system

Commissioning


Dimension drawing iCIM system

Commissioning


Position robot assembly vision station

Commissioning


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

4.3.1 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 600 kPA/6 bar and the pneumatic commissioning is realized.

4.3.2 Electric commissioning

The station must be provided with electrical voltage now. The station is provided with a power supply unit witch is provided with a voltage of 110/230 V. The delivered cables have 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.

To avoid problems during the operational process, individual protection (16A) of the installation is recommended.

4.3 Commissioning

Commissioning


4.3.3 Connecting communication cables

Communication cables example

If the robot assembly stationis to be connected to another installation, for example as described in complete process, communication takes place via Ethernet. The Ethernet cable from the Drive unit is fixed and not pluggable.

The following addresses have been allotted.

• Drive Unit IP#192.168.10.11 at Port 9002 • Camera robot assembly station Ethernet address # IP192.168.10.110

Vision Control Port 3246 Vision Data Port 3247

Commissioning


4.3.4 Establishing communication connections

The communication lines inside the components are hardly wired and it is not necessary to attach them. The pluggable connections are shown as graphics in the following.

Connections


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.

5.1.1 Behavior rules

• During the operation of the stations it is forbidden to grip in by hand. • With larger audience a mechanical protection of the stations is necessary. • Removing any cable under tension is forbidden. • Water has to be kept away from the plant. 5.1.2 Operation rules

• The stations only may be used by introduced persons. • The operation has to be carried out according to the operating instructions. • A pushing the different switches/push buttons of all control units unchecked has

to be stopped. • No workpiece carriers may be taken by the system.

5 Operation

5.1 General operation notes

Operation


5.2.1 Robot assembly station

Process description inside robot assembly station.

The robot assembly station is responsible for the assembly of an desk set in different variants. In Cosimir control it is possible to choose the respective workpiece.

Type 1 => base plate with two instruments and pen holder made from brass Type 2 => base plate with two instruments and pen holder made from aluminum

• Once a desk set is to be assembled a palette with a base plate is requested for placement onto the palette receptions on the station.

• A second palette with a pen holder, brass or aluminum - depending on the chosen order, is also requested and placed on the station.

• At first, the base plate is placed into the assembly position. • Then the first instrument is assembled in the base plate, if this option is chosen. • After assembling the first instrument, the second instrument is assembled and in

the same way, if this option is chosen. The instruments are coming from the magazines.

• The pen holder, coming from the palette, is assembled into the base plate. • At least a pen is inserted in the pen holder, the pen is coming from the magazine,

if this option is chosen. • The assembled desk set is returned to its retrieval position and stored in the

AS/RS station for further use.

The process for the different pen holders is the same, chose the pen holder in aluminum or brass is done in cosimir control.

5.2 Process description

Operation


For a better understanding, the following graphic should show the discharge of a task, started in COSIMIR FACTORY.

Task example

COSIMIR FACTORY is starting the robot program „MP.mb4. The following parameters are written to the program:

• Parameter 1: get a pallet from source position 15 (Transport delivery position) • Parameter 2: move it to target position 1 (– Pallet place 1) • Parameter 3 is 0 and is not considered.

5.3 Tasks

Operation


Order Type / Parameter Nr. Description

execprog Name of robot

program “MP” Move pallet

Parameter 1

Source position

1 Pallet place 1

2 Pallet place 2

3 Pallet place 3

4 Pallet place 4

15 Transport system delivery position

Parameter 2

Target position

1 Pallet place 1

2 Pallet place 2

3 Pallet place 3

4 Pallet place 4

15 Transport system delivery position

Parameter 3

Return-Code xxxxxx:n

N announce error number / see

table error codes



program “MBP” Move base plate

Parameter 1

Source position

1 Pallet place 1

2 Pallet place 2

3 Pallet place 3

4 Pallet place 4

5 Assembly position

Parameter 2

Target position

1 Pallet place 1

2 Pallet place 2

3 Pallet place 3

4 Pallet place 4

5 Assembly position

Parameter 3



table error codes

Operation




program “MPH” Move penholder

Parameter 1

Source position

1 Pallet place 1

2 Pallet place 2

3 Pallet place 3

4 Pallet place 4

5 Assembly position at base plate

Parameter 2

Target position

1 Pallet place 1

2 Pallet place 2

3 Pallet place 3

4 Pallet place 4

5 Assembly position at base plate

Parameter 3



table error codes



program “MINST” Move instrument

Parameter 1

Source position

1 Magazine 1

2 Magazine 2

3 Assembly position 1


Parameter 2

Target position



Parameter 3 -180°/180° Turning angle



table error codes



program “ASMP” Assemble pen

Parameter 1

Parameter 2

Parameter 3



table error codes

Operation


Error codes

Error codes are valid for all order codes (Return code)

Error Code Describtion

1 "No pallet at source position."

2 "Target position occupied."

3 "No pallet at target position."

4 "Assembly position occupied."

6 "No part in magazine available."

7 "No part in feeder available."

8 "No base plate clamped."

9 "No orientation found."

10 "Run-time-error CNC machine."

11 "Robot not ready for execution"

15 "Runtime error."

30 "Invalid input parameter 1"



999 "Invalid input parameter"

Operation


The operation panel has the following functions

• START button – start automatic mode • STOP button – stop automatic mode to cycle end • RESET button – start reset mode • AUT/MAN switch – not used • Q1 Lamp – not used • Q2 Lamp – Station not ready • S5 Illuminated pushbutton – quit emergency stop • S6 Emergency stop

The I/O interfaces and the plug- sockets are not used.

5.4 Operation panel

Operation


5.5.1 Start up conditions

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

It is required, that all of the stations are set up, aligned and adjusted, before starting the system. All of the transfer and assembly positions have to be adjusted or taught. The first start-up and teaching of each station is explained in detail in the station’s manual and has to be executed before.

5.5.2 general information

• Switch on distribution strips • Activate air supply for all stations min. 4 bar – max. 6 bar • Switch on the PC - COSIMIR FACTORY • Switch on all stations like described in the stations manual, reset the station and

start automatic mode • Switch on main switch of robot assembly station • Do not switch on Drive Unit of robot • Unlock and confirm all emergency switches of the station • The switch of the robots teach box has to be stand at disable • Key switch of the drive unit has to be at AUTO/EXT. • Switch on drive unit of the station

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.

CAUTION: DANGER OF COLLISION – DANGER OF INJURY. The robots arm has to moved out of the danger area. The reset mode is started at the operation panel.

1. If available remove all pallets and workpieces from the working positions and the machines.

2. Fill up all magazines 3. 'RESET'- lamp is flashing → request reset 4. Press 'RESET'- button for approx. 2 sec. 5. The robot makes his reference move, take care of all danger areas! 6. The 'RESET' lamp lights up if all of the initial positions are reached 7. Switch the 'AUTO/MAN'- key switch to 'AUTO'(permanent cycle).

'MAN'- position without function.

5.5 Start up system

5.6 Reset mode

Operation


5.7.1 Start automatic

1. The station is ready with the reset mode. 2. 'RESET'- lamp lights up and the 'START'- lamp is flashing → request to start the

station. 3. Press 'START'- button → automatic mode is active 4. Operating state is announced by lightening 'START' and 'RESET'- Lamp.

5.7.2 Automatic mode

Now the station is ready to get orders from COSIMIR FACTORY and to execute the orders.

5.7.3 Stop automatic

1. 'START' and 'RESET' – lamps are lightening and auto mode is active. 2. Press the 'STOP'- button 3. Operating state is announced with a flashing 'START'- lamp. 4. Active cycle is done complete. 5. If the cycle is ready the automatic mode is stopped. Press the 'START' button

and the automatic mode is starting again.

To shut down the station it is necessary that the production in COSIMIR FACTORY is already ended. Then the drive unit and afterwards the main switch can be switched off.

5.7 Automatic

5.8 Shut down the station

Operation


The robot is responsible for the workpiece handling.

RV-2AJ

Performance

Inputs 48 Inputs for communication

Outputs 48 Outputs for communication

Max. reservation 1 workpiece/pallet

5.9 Mitsubishi robot RV-2AJ

Operation


The Drive Unit is the controller for the robot. It is possible to extract the drive unit with an I/O module for further functions.

5.10.1 Functions

1. Plug for teach pendant 2. RS 232C– Interface for programming 3. Key switch for teach or auto modes 4. Display 5. Main switch 6. Emergency stop 7. Remove teach box button 8. Servo off button 9. Servo on button 10. Stop button 11. Start button 12. END button 13. RESET button 14. Down button 15. Up button 16. CHNG button

5.10 Drive Unit RV-2AJ

Operation


On the backside of the drive unit, there are some more plugs and interfaces.

17. I/O- interface 18. Emergency-plug/power supply 24V 19. CN1 for robot communication 20. CN2 for robot communication 21. Power supply 230V

Operation


5.10.2 Teach pendant RV-2AJ

To operate the robot in stand alone mode, the teach pendant is necessary. The buttons have different functions, depending on the different modes. With the key switch at the Drive unit, it is possible to choose the following three modes.

• Position Auto (OP) for stand alone mode. • Position Auto (EXT) for communication with other controller. • Position Teach for teach mode.

Teach pendant

Operation


5.10.3 Set up RV-2AJ

Drive-Unit

I/O-cable 50 pin

CN1

CN2Ria-Box

Programming PC

Drive-UnitTeach box

Robot RV-2AJ set up example for stand alone mode

Operation


5.10.4 To operate the robot

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

1. Connect power supply Drive unit / 230 V 2. Connect robot cables CN1 and CN2 from Drive unit to robot. 3. Plug teach pendant to Drive unit. 4. Emergency strap at back side of the Drive unit or emergency circuit to ria box. 5. Unlock Emergency stop at Drive unit and teach pendant. 6. Key switch ENABLE/DISABLE at teach pendant to enable. 7. Key switch Drive unit to teach (see example) 8. Switch on Drive unit / takes some time 9. Wait till display at teach pendant is ready 10. Press INP/EXE button – Menu teach pendant available 11. Choose TEACH mode 12. Press the black switch on the back side of the teach pendant, simultaneous

press the STEP/MOVE button. Now the drives are released*. (Click-sound)

* You have to execute this point the hole time to move the robot.

Now it is possible to move the robot.

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

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

tool length correction.

The modes are indicated in the teach pendants display. Choose one, the allocation off the buttons is shown in the following drawings.

To change the speed of the robot press

• +/FORWARD to get faster • -/BACKWRD to get slower

The speed is allocated in the teach pendant display in the right top corner. Speed between 3%-100% is available.

Operation


Functions of teach pendant in Joint mode

Z+

Z-

X-

X+Y-

Y+

B+

B-

A+

A-

XYZ-Mode

Functions of teach pendant in XYZ-Mode

Operation


Z-

Z+

X-

X+

B+

B-

A+A-

Tool-Mode

Without tool length correction

With tool length correction

Functions of teach pendant in Tool-Mode

Operation


5.10.5 Choose program

Processing cycle should not be active, otherwise stop cycle at operation panel.

Choose program at Drive unit

1. Press CHANG DSP button till P.*** announce in display 2. Press RESET button 3. Chose program with UP and DOWN buttons

Program number is announced in display of the drive unit 4. Press SVO ON button – drives are released 5. For program start press START button 5.10.6 Change program

Change program at Drive unit

1. Press CHANG DSP button till P.*** announce in display 2. Press STOP button to stop active program 3. Press RESET button 4. Choose program with UP and DOWN buttons

Program number is announced in display of the drive unit 5. Press SVO ON button – drives are released 6. For program start press START button

Operation


5.10.7 Teach position example

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

1. Connect power supply Drive unit / 230 V 2. Connect robot cables CN1 and CN2 from Drive unit to robot. 3. Connect PC with cosimir industrial / educational with Drive unit. 4. Plug teach pendant to Drive unit. 5. Emergency strap at back side of the Drive unit or emergency circuit to ria box. 6. Unlock Emergency stop at Drive unit and teach pendant. 7. Switch key ENABLE/DISABLE at teach pendant to enable. 8. Key switch Drive unit to teach 9. Switch on Drive unit / takes some time 10. Wait till display at teach pendant is ready 11. Press MENU button – Menu at teach pendant available 12. Positions have to be available in Drive unit. 13. Choose teach mode 14. Delete existing program name with POS and DELETE button 15. Press INP/EXE to list the different programs. 16. With ADD and RPL choose program. Task2 for program 2 a.s.o 17. Press INP/EXE to choose program 18. Press INP/EXE to activate program 19. Display looks as follows

PR:Task2ST:1 LN:10

20. To change a position, press POS. 21. Display looks like following

MS.POS(Px ) 22. Choose position with +/FORWRD and -/BACKWRD buttons 23. Select speed, press STEP/MOVE and • +/FORWARD to get faster • -/BACKWRD to get slower 24. Press the black switch on the back side of the teach pendant, simultaneous

press the STEP/MOVE button. Now the drives are released*. (Click-sound) 25. Press INP/EXE, robot moves to the chosen position 26. Now move the robot to the new position. Movement description see chapter (to

operate the robot) Example with XYZ mode. 27. Press STEP/MOVE and ADD simultaneously 28. Release ADD if you are sure that you want to overwrite the position. 29. Press ADD again, and the new position is saved. 30. Don’t forget to load the position list into the PC. * You have to execute this point the whole time to move the robot.

Operation


5.10.8 Interface Drive unit Inputs

Name Output/ Input

Input

Ria box

Output

Ria box

Input Robot PIN Robot Name

Operation

panel START button

S1

XMG1:13

RIA 1

X1:13

RIA 1

X0:16

INPUT 1

CN100:16 16 IN 1

STOP button S2

XMG1:14

RIA 1

X1:14

RIA 1

X0:17

INPUT 2

CN100:17 17 IN 2

AUTO/MAN

switch

S3

XMG1:15

RIA 1

X1:15

RIA 1

X0:18

INPUT 3

CN100:18 18 IN 3

RESET-button S4

XMG1:16

RIA 1

X1:16

RIA 1

X0:19

INPUT 4

CN100:19 19 IN 4

Robot

Station

Pallet 1

available

20B1/I0

XMB2:13

RIA 1

X2:13

RIA 1

X0:20

INPUT 5

CN100:20 20 IN 5

Pallet 2

available

20B2/I1

XMB2:14

RIA 1

X2:14

RIA 1

X0:21

INPUT 6

CN100:21 21 IN 6

Pallet 3

available

20B3/I2

XMB2:15

RIA 1

X2:15

RIA 1

X0:22

INPUT 7

CN100:22 22 IN 7

Pallet 4

available

20B4/I3

XMB2:16

RIA 1

X2:16

RIA 1

X0:40

INPUT 8

CN100:40 40 IN 8

Fixing cylinder

1 is fixed

10B1/I0

XMA2:13

RIA 1

X3:13

RIA 1

X0:41

INPUT 9

CN100:41 41 IN 9

Fixing cylinder

1 is fixed

10B2/I1

XMA2:14

RIA 1

X3:14

RIA 1

X0:42

INPUT 10

CN100:42 42 IN 10

Pallet available 10B3/I2

XMA2:15

RIA 1

X3:15

RIA 1

X0:43

INPUT 11

CN100:43 43 IN 11

Magazine 1

part available

10B4/I3

XMA2:16

RIA 1

X3:16

RIA 1

X0:44

INPUT 12

CN100:44 44 IN 12

Magazine 2

part available

10B5/I4

XMA2:17

RIA 1

X3:17

RIA 1

X0:45

INPUT 13

CN100:45 45 IN 13

Pen available 10B6/I5

XMA2:18

RIA 1

X3:18

RIA 1

X0:46

INPUT 14

CN100:46 46 IN 14

Pusher ballpen

Back position

10B7/I6

XMA2:19

RIA 1

X3:19

RIA 1

X0:47

INPUT 15

CN100:47 47 IN 15

Operation


5.10.9 Interface Drive unit Outputs

Name Output/ Input

Input

Ria box

Output

Ria box

Input Robot PIN Robot Name

Operation

panel Display START

H1

XMG1:1

RIA 1

X1:1

RIA 1

X0:4

OUTPUT 0

CN100:4 4 OUT 0

Display Initial

position

H2

XMG1:2

RIA 1

X1:2

RIA 1

X0:5

OUTPUT 1

CN100:5 5 OUT 1

Special

function1 lamp

H3

XMG1:3

RIA 1

X1:3

RIA 1

X0:6

OUTPUT 2

CN100:6 6 OUT 2

Special

function2 lamp

H4

XMG1:4

RIA 1

X1:4

RIA 1

X0:7

OUTPUT 3

CN100:7 7 OUT 3

Robot

Station

Unclamp fixing

cylinder 1+2

10M1/O0

XMA2:1

RIA 1

X3:1

RIA 1

X0:29

OUTPUT 4

CN100:29 29 OUT 4

Clamp fixing

cylinder 1+2

10M2/O1

XMA2:2

RIA 1

X3:2

RIA 1

X0:30

OUTPUT 5

CN100:30 30 OUT 5

Pusher ballpen

forward

21M1/O2

XMA2:3

RIA 1

X3:3

RIA 1

X0:31

OUTPUT 6

CN100:31 31 OUT 6

Pusher ballpen

backward

21M2/O3

XMA2:4

RIA 1

X3:4

RIA 1

X0:32

OUTPUT 7

CN100:32 32 OUT 7

Not used O4

XMA2:5

RIA 1

X3:5

Not used O5

XMA2:6

RIA 1

X3:6

Not used O6

XMA2:7

RIA 1

X3:7

Not used O7

XMA2:8

RIA 1

X3:8

Operation


5.10.10 Program documentation for CR1 and CR2 with ETHERNET

The basic structure consists of a main program Main.MB4 which is immediately started in the Slot 2 after switching the robot on. This is caused by the entry ALWAYS s in the Slot parameter SLT2. (see also: Parameter) After resetting and starting the automatic mode of the station, it is possible to start tasks on Slot 1 via Ethernet. These tasks can consist over respectively 3 parameters, for submit and return. These submit/return parameters are the global variables M_00-M_02. Before start the task over Ethernet, the values are written in this variables and at the end of the task, this values are read again. The tasks must have a certain structure so that Cosimir Control is been able to call them via Ethernet (s.a. task structure).

1. Switch on power supply 2. Reset emergency stop board (if available) 3. Turn Key switch of Teach Panel to Disable 4. Turn key switch at Drive unit to Auto/Ext 5. Switch on Drive unit 6. Station is ready it the reset lamp is flashing 7. Press reset pushbutton 8. Station is ready with reset mode if the start lamp is flashing 9. Press Start pushbutton to bring the Station in automatic mode 10. Now it is possible to start tasks via Ethernet

• M_00 : Submit/Return Parameter 1 • M_01 : Submit/Return Parameter 2 • M_02 : Submit/Return Parameter 3 • M_10: Automatic active • M_11: Station ready with reset • M_12: Emergency stop active • M_19: Handshake variable

Handling

Global Variables

Operation


The following parameters must set to configure a new Drive unit. After this the Drive unit must be switched of an on again.

Ethernet parameter:

• NETIP: 192.168.10.10 • NETPORT: 9000,9001,9002,9003,……………..

I/O- parameter:

• START: -1,-1 • ERRRESET: -1,-1 • SRVOFF: -1,-1 • SRVON: -1,-1 • IOENA: -1,-1

Slot parameter:

• SLT 1: ,CYC,START,1 • SLT 2: MAIN.MB4,CYC,ALWAYS,1 • SLT 3: ,CYC,START,1 • SLT 4: ERR.MB4,CYC,ERROR,1 • SLT 5: ,CYC,START, • ALWENA: 7

To be able to load the program Main.MB4 into the controller newly the Always in the Slot parameter SLT 2 must be changed into a start. After this switch of the drive unit and switch it on again. The program Main.Mb4 can be loaded quite normally again now. After this reverse the changes in the Slot parameter SLT 2, switch out and on the drive unit again.

Parameter

Attention

Operation


These programs must be loaded into the drive Unit. The program Main.Mb4 and ERR.MB4 can be loaded without changes. Init.Mb4 is a task adapted on the application. In the task TOUT.MB4 the period of time (DLY ) must be adapted to the application.

• MAIN.MB4 • INIT.MB4 • ERR.MB4 • TOUT.MB4

To call up the different application-specific tasks from Cosimir Control the tasks must have a specific structure. The following hand shake HShake1 must be integrated in the header of the program. The real hand shake takes place about the global variable M_19. Cosimir Control waits for hexadecimal value 55 and then the value 00 is written in M_19. The rest of the source code call the task TOUT (Timeout) in the Slot 5 and then the global variable M_10 checks if the station is in automatic mode.

490 *HShake1

500 M_19=&H55

510 wait M_19=&H00

520 IF M_PSA(5) = 0 THEN

530 XSTP 5

540 WAIT M_WAI(5) = 1

550 XRST 5

560 ENDIF

570 WAIT M_PSA(5) = 1

580 XLOAD 5,"TOUT"

590 XRUN 5,"TOUT",1

600 IF M_10 = 0 THEN

610 M_00 = 10

620 GOTO *HShake2

630 ENDIF

Main tasks

Task structure

Operation


The following hand shake must be available for Hshake2 at the end of the task.

Here the TOUT task is ended and the hand shake procedure carried out via the global variable M_19.

1360 *HShake2

1370 XSTP 5

1380 M_19=&HAA

1390 Wait M_19=&H00

1400 END

Operation


5.10.11 Robot programs

• MAIN.MB4 – Main program, starts automatically if the controller is switched on • INIT.MB4 – Reset program • ERR.MB4 – Program for error diagnostic • TOUT.MB4 – Program for timeout diagnostic • UBP.MB4 – global variables definition • COMM – Communication program for COSIMIR FACTORY

• “MP” – Move palette for example move palette from conveyor system onto palette holder 1 on station

Program tasks/positions

Operation


• “MBP” Move base plate

for example load a base plate into assembly position

• “MPH” – Move pen holder

for example insert pen holder into base plate, pen holder from magazine

Operation


• “MINST” – Move instrument

for example insert pen holder into base plate, pen holder from feeder

• “ASMP” – Assemble pen

for example insert pen into pen holder


This chapter refers to the technology of the robot assembly vision station.

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

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

Technical drawing robot assembly station

6 Technology

6.1 drawings

Technology


Pos. Name Dimensions

1 Width 700 mm

2 Length 1 110 mm

3 Hight 1 530 mm

4 Plate height 780 mm

5 Min. plate height 770 mm

6 Max. plate height 790 mm

7 Weight approx. 300 kg

6.2 Technical datas

Technology


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

• Palette reception • Pen/instrument magazine • Assembly module

6.3.1 Pallet reception

With this module it’s possible to pick up 4 pallets

Pallet reception

Performance

Inputs 4

Outputs /

Max. reservation 4 pallets

6.3 Modules in use

Technology


6.3.2 Pen/instrument magazine

The pen and the instrument are made available here. The magazine is also called feeder!

Pen/Instrument magazine

Performance

Inputs -

Outputs -

Max. reservation 15 pens / 10 instruments each

Technology


In this module the desk set is assembled.

Workpiece assembly module

Performance

Inputs 2

Outputs 2

Max. reservation 1

6.4 Assembly module

Technology


Transport direction work piece carrier

6.5 Workpiece direction


With the help of pneumatic cylinders, axes and grabs, the workpieces and the workpiece carriers get clamped, distributed or just moved. The valve terminal necessary for the control, consist from different, the use purpose, individual valves. The cylinders and the valves are described in the following.

Example Valve terminal

Pos. Name

1 Odernumber 18 200

2 Ordername 10P-10-6B-IC-N-V-10M+HZ

7 Pneumatic

7.1 The valve terminal

Pneumatic


The pressure in the supply line must not exceed 10 bar.

A fine filter has to be installed, to prevent contamination by rust or similar.

A stop cock is required for the supply of the installation.

The pressure regulators should be set in between 5 and 6 bar. The filter and water separators require maintenance according to the instructions of the documentation of these components.

The exact allocation of the valve terminal can be found in the pneumatic plan.

Service unit

7.2 Pneumatic supply


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

To give you a better 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 supply is 230 V.

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.

The control of the station is done by the drive unit of the robot. See respective chapter.

8 Electrical system

8.1 Power supply

8.2 Controller

Electrical system


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

8.3.1 I/O-Components

The operating strip, the moduls from the profil plate and the z-axis are pluggable connected via I/O-terminals to the SM323 I/O-cards from the control.

So that a perfect communication can be ensured, the I/O interface is standardized. The I/O terminal is at all work positions at the disposal.

I/O-Terminal

Technical data

Plug type IEEE 488 24 pins

Inputs 8

Outputs 8

Current consumption Max. 1A/PIN

Power supply 24 VDC

8.3 Wiring

Electrical system


123456789101112

222324

131415161718192021

OUT BIT 0OUT BIT 1OUT BIT 2OUT BIT 3OUT BIT 4OUT BIT 5OUT BIT 6OUT BIT 7POWER 24 VDCPOWER 24 VDCPOWER 0 VDCPOWER 0 VDC

IN BIT 0IN BIT 1IN BIT 2IN BIT 3IN BIT 4IN BIT 5IN BIT 6IN BIT 7POWER 24 VDCPOWER 24 VDCPOWER 0 VDCPOWER 0 VDC

syslink pin assignment01 Bit 0 Output word white02 Bit 1 Output word brown03 Bit 2 Output word green04 Bit 3 Output word yellow05 Bit 4 Output word grey06 Bit 5 Output word pink07 Bit 6 Output word blue08 Bit 7 Output word red09 24 V Power supply black1011 0 V Power supply pink-brown12 0 V Power supply purple

13 Bit 0 Input word grey-pink14 Bit 1 Input word red-blue15 Bit 2 Input word white-green16 Bit 3 Input word brown-green17 Bit 4 Input word white-yellow18 Bit 5 Input word yellow-brown19 Bit 6 Input word white-grey20 Bit 7 Input word grey-brown21 24 V Power supply white-pink2223 0 V Power supply white-blue24

Allocation I/O- Terminal

Clamp Bit Function Colour Clamp Bit Function Colour

01 0 Output White 13 0 Input Grey-pink

02 1 Output Brown 14 1 Input Red-blue

03 2 Output Green 15 2 Input White-green

04 3 Output Yellow 16 3 Input Brown-green

05 4 Output Grey 17 4 Input White-yellow

06 5 Output Pink 18 5 Input Yellow-brown

07 6 Output Blue 19 6 Input White-grey

08 7 Output Red 20 7 Input Grey-brown

09 24V Power supply Black 21 24V

Power

supply White-pink

10 22

11 0V Power supply Pink-brown 23 0V

Power

supply White-blue

12 0V Power supply purple 24

Documents

iCIM FC Robot RV2AJ Assembly Vision A008