Professional Documents
Culture Documents
Manual
Robot assembly
vision station
Order-NR.:
Designation iCIM_FC_Robot_RV2AJ_Assembly_Vision_A008.doc
Printed: November 08
Autor: Schober
Graphics: Schober
Layout: Schober
Internet: www.festo.com/didactic
e-mail: did@festo.com
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.
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.
• 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.
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)
2 Introduction ______________________________________________________ 9
2.1 General______________________________________________________ 9
5.10.10 Program documentation for CR1 and CR2 with ETHERNET ______ 52
2.1 General 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.
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.
2.2 Robot assembly The robot assembly stationis responsible for the assembly of an desk set in different
station 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.
If the station is operated without the iCIM System, in “stand alone” mode, it is
possible to make training on the robot.
6 Magazine 2
2.3 Didactic structure 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.
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.
• 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
2.4 Duty of the operating The operating authority undertakes to ensure that the ICIM is used only by persons
authority 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.
2.5 Duty of trainees 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.
2.6 Warranty and In principle all our „Terms and Conditions of Sale“ apply. These are available to the
liability 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:
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.
2.7 Intended use 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:
2.8 Important notes 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.
Furthermore, the rules and regulations for the prevention of accidents applicable to
the place of use must be observed.
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.
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.
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.
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.
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.
Trainees are permitted to work with the machine only under strict supervision of an
experienced person or an instructor.
Activities in the areas of maintenance, service and repair are to be carried out by
only persons with appropriate technical qualifications.
3.3 Emergency stop The emergency stop system is controlled by a higher safety control unit. The
system description is noted in the manual of the transport system.
In this manual the following danger designations and signs are being used:
DANGER !
Failure to pay attention to this symbol may result in serious health damage, which
may even lead to life-threatening injuries.
IMPORTANT
Failure to pay attention to this symbol may result in damages to the machine or to
its surroundings.
This symbol assists you to make optimal use of all of your machine’s functions.
4.1 Transport 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 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.
i 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.
Check the scope of delivery against the delivery note and the order. Festo Didactic
must be notified immediately of any discrepancies.
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.
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.
4.3 Commissioning Commissioning of the system can ensue only, once all of the stations are connected
to their definite position.
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.
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.
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.
5.1 General operation The stations require some rules of operation witch should be observed. If they are
notes not complied, faults in the processes are possible. Dangers for the physical health
also cannot be excluded.
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.
5.3 Tasks 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:
Error codes
Error codes are valid for all order codes (Return code)
15 "Runtime error."
The I/O interfaces and the plug- sockets are not used.
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.
5.6 Reset mode 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.
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.
Now the station is ready to get orders from COSIMIR FACTORY and to execute the
orders.
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.
5.8 Shut down the To shut down the station it is necessary that the production in COSIMIR FACTORY is
station already ended. Then the drive unit and afterwards the main switch can be switched
off.
5.9 Mitsubishi robot The robot is responsible for the workpiece handling.
RV-2AJ
RV-2AJ
Performance
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
On the backside of the drive unit, there are some more plugs and interfaces.
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.
Teach pendant
Drive-Unit
CN1
CN2
Ria-Box
I/O-cable 50 pin
Programming PC
* You have to execute this point the hole time to move the robot.
The following three modes are available for to move the robot.
The modes are indicated in the teach pendants display. Choose one, the allocation
off the buttons is shown in the following drawings.
The speed is allocated in the teach pendant display in the right top corner. Speed
between 3%-100% is available.
XYZ-Mode
B+
Z+ A-
A+
X- Y+ B-
Y- X+
Z-
Functions of teach pendant in XYZ-Mode
B+
Z-
Tool-Mode
X- B-
X+
A-
A+ Z+
Processing cycle should not be active, otherwise stop cycle at operation panel.
* You have to execute this point the whole time to move the robot.
O4 RIA 1
Not used
XMA2:5 X3:5
O5 RIA 1
Not used
XMA2:6 X3:6
O6 RIA 1
Not used
XMA2:7 X3:7
O7 RIA 1
Not used
XMA2:8 X3:8
Parameter 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
Attention 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.
Main tasks 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
Task structure 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
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
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.
6.1 drawings
1 Width 700 mm
2 Length 1 110 mm
3 Hight 1 530 mm
6.3 Modules in use The station is made up of a number of different function modules.
• Palette reception
• Pen/instrument magazine
• Assembly module
Pallet reception
Performance
Inputs 4
Outputs /
The pen and the instrument are made available here. The magazine is also called
feeder!
Pen/Instrument magazine
Performance
Inputs -
Outputs -
Performance
Inputs 2
Outputs 2
Max. reservation 1
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.
Pos. Name
1 Odernumber 18 200
2 Ordername 10P-10-6B-IC-N-V-10M+HZ
7.2 Pneumatic supply The pressure in the supply line must not exceed 10 bar.
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
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.
8.1 Power supply 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.
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.
8.2 Controller The control of the station is done by the drive unit of the robot. See respective
chapter.
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 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.
I/O-Terminal
Technical data
Inputs 8
Outputs 8
09 Power
24V Power supply Black 21 24V White-pink
supply
10 22
11 Power
0V Power supply Pink-brown 23 0V White-blue
supply