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FLEXIBLE ASSEMBLY SYSTEM

FAS200

User Manual for FAS200

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INDEX

INDEX ......................................................................................................................................................... 4

CONFIGURATION .......................................................................................................................... 5

GENERAL OVERVIEW: ................................................................................................................ 9

FAS-230

LINEAR TRANSFER

MODULE:

TRANSPORT

SYSTEM ........................................................ 13

TROUB-200

FAULT

SIMULATION

SYSTEM ................................................................................... 17

FAS-201

BASE

EEDING

/VERIFICATION

MODULE

............................................................................ 18

FAS-202

BASE

REJECTING

TRANSFERING MODULE

............................................................................... 23

FAS-203

BEARING

EEDING

/TRANSFERING

MODULE

.................................................................... 27

FAS-204

BEARING

MEASURING/TRANSFERING

MODULE

........................................................... 31

FAS-205

HYDRAULIC

PRESSING

MODULE

...................................................................................... 36

FAS-206

HYDRAULIC

PRESS

TRANSFERING

MODULE

................................................................. 41

FAS-207

SHAFT

CLASSIFICATION

MODULE ................................................................................ 45

FAS-208

SHAFT

REJECTING

RANSFERING MODULE

............................................................................ 51

FAS-209

COVER

CLASSIFICATION

MODULE

................................................................................... 56

FAS-210

COVER

REJECTING/TRANSFERING

MODULE

.................................................................. 63

FAS-211

SCREWS

DISPENSING

MODULE

.......................................................................................... 67

FAS-212

SCREWS

INSERTION

MODULE

............................................................................................ 71

FAS-213

ROBOTIZED SCREWING MODULE

.............................................................................................. 75

FAS-214

RANSFERING AND VISION INSPECTION MODULE

.................................................................... 79

FAS-215

AFTER

VISUAL

INSPECTION

REJECTING

ODULE

....................................................... 84

FAS-216

AREHOUSE MODULE

............................................................................................................. 87

FAS-220

PALLET

TRANSFER

MODULE

.............................................................................................. 91

APPENDIX A: FAULT GENERATION

APPENDIX B: ELECTRICAL DIAGRAMS

APPENDIX C: PNEUMATIC DIAGRAMS

APPENDIX D: GRAFCETs / SFCs

APPENDIX E: MECHANICAL DIAGRAMS

Summary of Contents for FAS-200

Page 1: ...F FL LE EX XI IB BL LE E I IN NT TE EG GR RA AT TE ED D A AS SS SE EM MB BL LI IN NG G S SY YS ST TE EM MS S F FA AS S 2 20 00 0 ...

Page 2: ...FAS 200 USER MANUAL ...

Page 3: ...raining in flexible integrated assembling systems F F Fl l le e ex x xi i ib b bl l le e e A A As s ss s se e em m mb b bl l ly y y S S Sy y ys s st t te e em m m F F FA A AS S S 2 2 20 0 00 0 0 Technical Description ...

Page 4: ...LCs needed for system control are included with mains supply connection and users may design their own electrical control gear based on other different PLCs 6 Each of the most of the modules incorporates a key protected Fault Generation System which makes it possible to work on diagnostic and repair capabilities using the Switches methodology 7 The FAS200 cell has been designed for assembly of a t...

Page 5: ... MEASURING ETC integrating different technologies including Pneumatics Electro pneumatics Hydraulics Electro hydraulics Electrical Actuators Robotics Manipulation Industrial Communications Control Systems Electric Automatisms Safety Devices Basic Mechanical Systems Artificial Vision Systems and so on 10 It has been conceived and designed by a knowledgeable team with wide experience in both the ind...

Page 6: ... HYDRAULIC PRESS TRANSFERING MODULE 41 FAS 207 SHAFT CLASSIFICATION MODULE 45 FAS 208 SHAFT REJECTING TRANSFERING MODULE 51 FAS 209 COVER CLASSIFICATION MODULE 56 FAS 210 COVER REJECTING TRANSFERING MODULE 63 FAS 211 SCREWS DISPENSING MODULE 67 FAS 212 SCREWS INSERTION MODULE 71 FAS 213 ROBOTIZED SCREWING MODULE 75 FAS 214 TRANSFERING AND VISION INSPECTION MODULE 79 FAS 215 AFTER VISUAL INSPECTION...

Page 7: ...ment and in keeping with industrial reality The technologies included in its different assembly modules as well as the assembly process with several variants allow the user to develop the professional skills required by today s automated industry FAS200 MODULES FAS200 is comprised of different stations each performing a part of assembly process Figure 1 System FAS200 with complete configuration ...

Page 8: ...odule 1 FAS 207 Shaft classification module 1 FAS 208 Shaft Rejecting Transfering module 1 FAS 209 Cover classification module 1 FAS 210 Cover Rejecting Transfering module 1 FAS 211 Screws dispensing module 1 FAS 212 Screws insertion module 1 FAS 213 Robotized screwing module 1 FAS 214 Transfering and vision inspection module 1 FAS 215 After visual inspection rejecting module 1 FAS 216 Warehouse m...

Page 9: ...ation of 8 modules STATION Qty FAS 201 Base Feeding Verification module 1 FAS 202 Base Rejecting Transfering module 1 FAS 203 Bearing Feeding Transfering module 1 FAS 204 Bearing Measuring Transfering module 1 FAS 209 Cover classification module 1 FAS 210 Cover Rejecting Transfering module 1 FAS 213 Robotized screwing module 1 FAS 216 Warehouse module 1 FAS 230 Linear transfer for 4 modules 2 ...

Page 10: ...ystem FAS200 Number of modules 8 modules Number of modular conveyors 2 units of linear transfer for 4 modules Control SIEMENS PLC of CPU 1214C serie Field and control network ETHERNET Figure 3 Communication of the system FAS200 with configuration of 8 modules ...

Page 11: ...Maintenance Automatic Control and Regulation Systems Figure 4 System FAS200 with different configurations It enables the development of various skills associated with pneumatic electro pneumatic electrical robotic and handling automatisms programming and PLC technologies industrial communications supervision quality control and fault diagnosis and repair It also allows the study of a wide range of...

Page 12: ...ermined parts with a total of 24 different possibilities Figure 5 Turning mechanism Figure 6 Turning mechanism components Parts are transported between the different modules by an automated linear transfer with corresponding stoppers and precision lifters positioners Parts are mounted on pallets Figure 7 Linear transfer for 4 modules Figure 8 Linear transfer for 8 modules ...

Page 13: ...in completely independent in a single mode or with its complementary module in a couple mode requiring reprogramming of the control Figure 9 FAS201 module a single mode Figure 10 FAS201 and FAS202 modules in couple module without any linear transfer Each station has its own electrical panel where the wiring system and PLC are fully visible for study while new elements may be fitted to the panel if...

Page 14: ...tiple slots to allow all types of extension and modification The assembly process performed turning mechanism is as follows Process A Feed body or base to which the other parts are assembled and verification of its orientation Process B Pick and Place bearing and measurement of its height Process C Press bearing in hydraulically Process D Pick and Place shaft and verification of its orientation an...

Page 15: ...STEM Figure 13 FAS230 Linear Transfer Module The transport system is composed by 2 meters long lines admitting up to four modules each 2 9 meters long lines admitting up to six modules each for special case which links the modules to facilitate the envisaged assembly process Figure 14 Transport system ...

Page 16: ...ome configurations the communication connections Figure 15 Longitudinal channel for connections The modular transfer incorporates a pallet assembly to transport parts and assemblies across the handling stations The pallets and the transfer stoppers incorporate a binary coding system using inductive detectors which allow the Control System to identify the position of each pallet at any time Figure ...

Page 17: ...fications as the system FAS200 is sent mechanically adjusted and programmed to the specific distribution and any variation of the distribution would also reprogram the control of the system TECHNICAL DATA Modular transfer Dimensions each transfer for 4 modules 1 section 2000 x 130 mm Height 970 mm Dimensions each transfer for 6 modules 1 section 2900 x 130 mm Height 970 mm Drive each transfer for ...

Page 18: ...h guide Ø16 Stroke 30mm MGPM16 30Z with flow regulators Controlled by 5 2 way monostable solenoid valve 1 Two directions rotary table max 90º MSUB3 90S with flow regulators Controlled by 5 2 way monostable solenoid valve Sensors each 2 modules 3 Inductive detectors OMRON E2A M12KS04 M1 B1 1 Microswitch OMRON V 166 1C5 ...

Page 19: ...epending of the configuration Figure 18 TROUB 200 in the Figure 19 TROUB 200 in a side of electrical panel module The system consists of a lockable box containing 16 switches which when operated cause a fault in the module In the Appendix A there are more details about this Fault Simulation System with a series of tables per module where the error symptom suspicious components and the final faulty...

Page 20: ...he support for the turning mechanism verifies its orientation and moves it to the final position loading position located in the transfer system of the next module Figure 21 Manipulators of the first module This operation begins when the pallet is positioned opposite the second module held in a determined location by a stopper on the linear transfer Confirmation that the pallet is in the correct p...

Page 21: ...y be divided into a series of manipulators Each sub division has been made by considering it as a set of components which performs a specific operation within the whole process carried out at the module Body feeder The feeder which supplies the body is of the gravity feed type in that the bodies are stored in a stack so that when the bottom one is removed the next falls into place under the effect...

Page 22: ... cannot complete its stroke and the magnetic detector on the cylinder is not activated A signal to this effect enters the PLC resulting in an indication that the position of the body is incorrect Figure 24 Orientation checker Movement to transfer point A pneumatic cylinder with a pusher at its end is used to situate the body at the point from which it will be loaded on the pallet on the following ...

Page 23: ...n detectors Controlled by 5 2 way monostable solenoid valve Sensors Reed type magnetic detectors D C73L Inductive sensor OMRON E2A M12KS04 WP B1 Position verification Actuators Double acting cylinders Ø12 Stroke 50mm CD85N12 50 A with flow regulators and end position detector Controlled by 5 2 way monostable solenoid valve Sensors Reed type magnetic detector D A73CL Transfer manipulator Actuators ...

Page 24: ...lectrical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 9 inputs 5 outputs Supply module 24V 60W PLC control CPU with digital inputs outputs Communication module for PLC network connection ...

Page 25: ...ecting Transfering Module FUNCTION OF THE MODULE This second module is complementary to previous one This module rejects of incorrect body or places the body on the pallet depending of the signal body OK from the PLC of the preceding module after verification of the base orientation Figure 27 Manipulators of the second module ...

Page 26: ...ration within the whole process carried out at the module Rejection of incorrect body If the verification process shows the orientation of the body to be incorrect a single acting cylinder moves it towards a ramp leaving the space clear for a new body Figure 28 Rejection cylinder Placing body onto the pallet A two cartesian axes manipulator is used to place the body on the pallet that is waiting o...

Page 27: ...lator and pressure gauge Control panel Start stop reset pushbuttons Emergency stop button main switch on off mode selector auto man and error pilot indicator Composition of module manipulators Inverted body rejection manipulator Actuators Single acting ejection cylinder Ø10 Stroke 15mm CJPB10 15H6 Controlled by 3 2 way monostable solenoid valve Pallet insertion module Actuators Horizontal axis Par...

Page 28: ... cups Ø16 ZPT16CNK10 B5 A10 with ejector to generate vacuum ZU07S Controlled by 3 2 way bistable solenoid valve Sensors Reed type magnetic detectors D Z73L Vacuum switch with PNP output PS1100 R06L Electrical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 13 inputs 8 outputs Supply module 24V 60W PLC control CPU with digital in...

Page 29: ...NCTION OF THE MODULE This third module feeds the bearing which is going to be placed inside the housing formed in the body by the next module Also this module transfer the bearing to the measurement position located on the next module where the height is measured to differentiate between the two sizes of bearings Figure 32 Manipulators of the third module ...

Page 30: ...s been made by considering it as a set of components which performs a specific operation within the whole process carried out at the module Bearing feeder The feeder which supplies the bearing is of the gravity feed type in that the bearings are stored in a column so that when the bottom one is removed the bearing is extracted at the moment the cycle starts the next falls into place under the effe...

Page 31: ...he inner part of the bearing This arm houses a mechanism consisting of a toothed belt and two pinions the purpose of which is to keep the gripper orientation throughout the turning movement so that it can reach the measuring point in horizontal position Figure 35 Transfer manipulator TECHNICAL DATA Dimensions Table of slotted aluminium 450 x 582 mm Height 900 mm Air treatment unit Filter to 5 µm p...

Page 32: ...uator Double rack and pinion Ø50 max 180º MSQB50A with flow regulators and 0º 90º and 180º position detectors Controlled by 5 3 way solenoid valve mid position closed Holding arm Two finger parallel opening gripper MHK2 16D Controlled by 5 2 way bistable solenoid valve Sensors Reed type magnetic detectors D A93L Electrical control panel Mounted on perforated mesh Accessible terminal plate with sup...

Page 33: ...ANSFERING MODULE Figure 36 FAS204 Bearing Measuring Transfering Module FUNCTION OF THE MODULE This fourth module is complementary to previous one Is in this module where the height is measured to differentiate between the two sizes of bearings Figure 37 Manipulators of the fourth module ...

Page 34: ...the pallet brought by the belt conveyor and carrying the body fed and assembled by the previous modules The bearing fitting operation requires the pallet carrying the body to be precisely situated in a predetermined place To achieve this precision once the pallet has been retained by a stopper it is lifted by a pneumatic cylinder and centred at the same time by four pins which fit inside housings ...

Page 35: ...ading The touch trigger consists of a linear potentiometer with an output processed via an analogue module included in the PLC After measurement the lifter returns to its original position Then in case the height does not correspond to the selected one a cylinder pushes the bearing towards a ramp Bearing insertion The final operation is performed by a manipulator comprising a rotary linear system ...

Page 36: ...e 5mm CQ2B12 5S Controlled by 3 2 way monostable solenoid valve Vertical axis Rodless cylinder Ø16 Stroke 250mm MY1M16G 250 with flow regulators and initial end position detectors Controlled by 5 2 way bistable solenoid valve Incorrect bearing rejection Double acting cylinder Ø10 Stroke 40mm CD85N10 40 B with flow regulators Controlled by 5 2 way monostable solenoid valve Sensors Reed type magneti...

Page 37: ...inger parallel opening gripper MHK2 16D Controlled by 5 2 way bistable solenoid valve Sensors Reed type magnetic detectors D A93L Electrical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 14 digital inputs 1 analogue input 11 outputs Supply module 24V 60W PLC control CPU with digital inputs outputs Analogue inputs card Communic...

Page 38: ...insertion operation performed by the preceding modules this fifth module carries out the task of pressing the bearing firmly into the body to fix it securely In actual fact this pressing operation is not actually carried out instead it is only simulated so that the finished assembly may be dismantled easily and the component parts reused Figure 41 Manipulators of the fifth module ...

Page 39: ... Confirmation that the pallet is in the correct position is provided by a microswitch which sends the appropriate signal to the PLC of the sixth module which in turn sends the signal start cycle to the PLC of this fifth module INTEGRAL PARTS The fifth module like the others may be divided into a series of manipulators Each sub division has been made by considering it as a set of components which p...

Page 40: ...screen is lifted and the assembly is pushed to the unloading position Figure 42 Pressing of bearing Feeder Extractor of the press The body to be fed in to the press is deposited on a platform of the sixth module fitted with two double acting pneumatic cylinders The first one in the sixth module effects the transfer from the loading unloading point to the press while the second one in this fifth mo...

Page 41: ...cylinder Ø15 Stroke 100mm CXSM15 100 with flow regulators and end position detector Controlled by 5 2 way monostable solenoid valve Pressing Compact double acting hydraulic cylinder Ø40 Stroke 50mm CHDKGB40 50M with flow regulators and initial middle end position detectors Controlled by 4 3 way solenoid valve mid position A B closed and P T connected Sensors Reed type magnetic detectors D Z73L Pre...

Page 42: ... terminal plate with supply connections and coded I Os I O station 13 inputs 6 outputs Supply module 24V 60W Safety relay with safety switch PLC control CPU with digital inputs outputs Communication module for PLC network connection Hydraulic unit Three phase motor 230 400V 0 50CV 1450rpm Pressure gauge Pressure limiter ...

Page 43: ...sfering Module FUNCTION OF THE MODULE This sixth module is complementary to previous one Is in this module where the base bearing assembly is transfered from the pallet of the lineal conveyor to the platform of this module and then from this platform to the hydraulic press of the previous module Figure 45 Manipulators of the sixth module ...

Page 44: ...nloading point inside the module This handling and the reverse process of unloading following pressing are performed by a pneumatic rotary actuator Figure 46 Insertion extraction of assembly This actuator incorporates an arm with a set of four suction cups at its end whose job is to hold the part by means of an internal vacuum generated by an ejector To keep the body permanently horizontal through...

Page 45: ...off mode selector auto man and error pilot indicator Composition of module manipulators Assembly insertion extraction manipulator Actuators Rotary actuator Double rack and pinion type Ø50 max 180º MSQB50A with flow regulators and 0º 90º and 180º position detectors Controlled by 5 3 way solenoid valve mid position closed Holding arm 4 Suction cups Ø16 ZPT16UN B5 with ejector to generate vacuum ZU07...

Page 46: ...f stroke position detectors Controlled by 5 2 way monostable solenoid valves Sensors Reed type magnetic detectors D A73CL Electrical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 14 digital inputs 7 outputs Supply module 24V 60W PLC control CPU with digital inputs outputs Communication module for PLC network connection ...

Page 47: ...of the previous modules The need for appropriate checks to determine which type of shaft is to be assembled at each module cycle means that this module is one of the most complex in terms of the operations to be carried out It is also essential that the module control coordinates part selection operations in accordance with the commands supplied by the master responsible for production management ...

Page 48: ...nd plastic shaft and the orientation of the shaft The confirmation of the presence the orientation and the material of the shaft is got by some sensors an inductive detector a capacitive detector and a pneumatic cylinder with magnetic detector at the end of its stroke turning on some internal flags of the PLC the previously mentioned signals This operation begins when the pallet is positioned oppo...

Page 49: ...d angular advance Figure 51 Pusher cylinder There are a further two stop cylinders which function alternately one moving which holds the plate during the turn and another fixed cylinder which locks the plate in position when movement has ceased In this way the plate is held firmly and the pusher cylinder can return to its initial position to await a new cycle Shaft feeder The shafts stored in a gr...

Page 50: ...he end of its travel if the shaft is not in its proper orientation Figure 53 Shaft orientation checker Material detection position As described above this module offers the possibility of working with aluminium or black nylon To differentiate these two types and detect the presence of the shaft the next index plate position is fitted with an inductive detector and a capacitive detector which suppl...

Page 51: ...button main switch on off mode selector auto man no material indicator and error pilot indicator Composition of station modules Index plate Actuators Pusher cylinder Compact double acting cylinder Ø25 Stroke 40mm CDQ2B25 40D with flow regulators and initial position detector Controlled by 5 2 way monostable solenoid valve Locking cylinders 2 Compact cylinders Ø16 Stroke 10mm CQ2B16 10D Controlled ...

Page 52: ...sition detector Controlled by 5 2 way monostable solenoid valve Sensors Reed type magnetic detector D A73CL Material detectors Sensors Inductive sensor OMRON E2A M18KS08 WP Capacitive sensor OMRON E2K X4MF1 Electrical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 8 inputs 6 outputs Supply module 24V 60W PLC control CPU with di...

Page 53: ...le rejects the shaft or places it inside the housing of the body on the pallet depending of the signal about the shaft material from the PLC of the previous module Figure 56 Manipulators of this module This operation begins when the pallet is positioned opposite the module held in a determined location by a stopper on the linear transfer and when the PLC of the seventh module sends the signal end ...

Page 54: ...been made by considering it as a set of components which performs a specific operation within the whole process carried out at the module Shaft insertion in assembly Shaft insertion carried out at the last of the index plate of the previous module is performed by a rotary linear type manipulator This rotary linear cylinder makes it possible for a single component to pick up the shaft take it to th...

Page 55: ... for the various assemblies This means a need for some element to reject the shaft if it is not of the type indicated an operation carried out at the fifth index plate of the previous module and involving a manipulator which removes the shaft from the plate on receiving the corresponding command This element takes the form of a two axis manipulator at the extreme end of which is a suction cup to h...

Page 56: ...ostable solenoid valves Holding arm Suction cup Ø10 ZPT10CNK10 B5 A10 with vacuum generating ejector ZU07S Controlled by two 3 2 way biestable solenoid valve Sensors Reed type magnetic detectors D A73CL Vacuum switch PNP output PS 1100 R06L Incorrect shaft ejection module Actuators Horizontal axis Double acting parallel rod cylinder Ø15 Stroke 100mm CXSM15 100 with flow regulators and initial end ...

Page 57: ... Vacuum switch PNP output PS 1100 R06L Electrical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 18 inputs 11 outputs Supply module 24V 60W PLC control CPU with digital inputs outputs Communication module for PLC network connection ...

Page 58: ... this purpose The cover serves to retain the turning mechanism shaft mounted at the previous modules While the preceding modules saw the introduction of a variant in the form of different materials for the shaft this module increases the number of variants by offering the choice of three different materials for the cover aluminium white nylon and black nylon in addition to a choice of two differen...

Page 59: ...it onside the housing of the body on the pallet depending of the signals metal cover plastic cover black cover white cover tall cover and short cover The confirmation of the cover is the correct one material color and height is got by some sensors an inductive detector a photoelectric detector and a pneumatic cylinder with stroke reading turning on some internal flags of the PLC the previously men...

Page 60: ...chieve this effect the system incorporates a pneumatic pusher cylinder with back and forth movement giving the required angular advance Figure 62 Index plate There are a further two stop cylinders which function alternately one moving which holds the plate during the turn and another fixed cylinder which locks the plate in position when movement has ceased In this way the plate is held firmly and ...

Page 61: ...ic sensor Cover measuring position The fact that covers of two different heights may be assembled necessitates a height measuring device Owing to the teaching and training objective for which the cell has been designed various solutions have been used to perform similar operations so that while components such as pneumatic cylinders with correct height detectors or analogue output touch probes hav...

Page 62: ...luminium white nylon and black nylon respectively To differentiate these types the next index plate position is fitted with an inductive detector and a photoelectric detector which supply the necessary signals to the PLC Detection of the metal covers necessitates the use of a inductive sensor which supplies a signal when the part detected is made of metal The final cover differentiation process is...

Page 63: ...noid valve Locking cylinders 2 Compact cylinders Ø16 Stroke 10mm CQ2B16 10D Controlled by 5 2 way monostable solenoid valve Sensors Reed type magnetic detector D A73CL Cover feeder Magazine capacity 18 covers Actuators 2 Two finger parallel opening pneumatic gripper MHZ2 20D with a flow regulator Controlled by two 5 2 way monostable solenoid valves Sensors Fiber optic sensor OMRON E32 DC200 E3X NA...

Page 64: ...ric sensor OMRON E3F2 DS30B4 Electrical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 8 digital inputs 2 counter inputs 7 outputs Supply module 24V 60W PLC control CPU with digital inputs outputs and counter inputs Communication module for PLC network connection ...

Page 65: ...ver Rejecting Transfering Module FUNCTION OF THE MODULE This tenth module is complementary to previous one This module rejects the cover or places it onside the housing of the body on the pallet depending of the signal about the cover material from the PLC of the previous module Figure 68 Manipulators of the tenth module ...

Page 66: ...lators Each sub division has been made by considering it as a set of components which performs a specific operation within the whole process carried out at the module Rejection of incorrect cover If the cover reaches the last but one index plate position on the previous module and the various material or height sensors have indicated that it is not of the material or height indicated by the main c...

Page 67: ...manding rod instroking and outstroking as well as turns to left or right It is this cylinder which turns an arm fitted with a parallel opening gripper used to holds the cover throughout the movement which is lifted and turned towards the unloading point by a rotary linear pneumatic actuator Figure 70 Insertion manipulator TECHNICAL DATA Dimensions Table of slotted aluminium 450 x 582 mm Height 900...

Page 68: ...enoid valve Sensors Reed type magnetic detectors D Z73L Vacuum switch with PNP output PS1100 R06L Cover insertion module Actuators Compact linear and rotary movement cylinder Ø32 Stroke 25mm EMRQBS32 25CB with flow regulators and initial end of travel detection for linear movement and 0º and 180º detection for rotary movement Controlled by two 5 2 way monostable solenoid valves Holding arm Two fin...

Page 69: ...e FUNCTION OF THE MODULE Following insertion operations for the bearing shaft and cover performed by the preceding modules this eleventh module carries out the task of feeding the screws that the next module is going to insert them in the four holes of the base or body for this purpose Figure 72 Manipulators of the eleventh module ...

Page 70: ... components which performs a specific operation within the whole process carried out at the module Screws feeder The screws to be inserted are stored in a vertical gravity feeder from where they are unloaded onto a housing via a step by step feed system involving two pneumatic cylinders working in a permanent counterpoise position so that while the lower one instrokes to let the next screw fall fr...

Page 71: ...akes it possible to determine when the screws loaded in the feeder have run out Figure 74 Photoelectric cell with fiber optic TECHNICAL DATA Dimensions Table of slotted aluminium 450 x 600 mm Height 900 mm Air treatment unit Filter to 5 µm pressure regulator and pressure gauge Control panel Start stop reset pushbuttons Emergency stop button main switch on off mode selector auto man no material ind...

Page 72: ...ors Controlled by 5 2 way bistable solenoid valve Sensors Reed type magnetic detectors D Z73L Photoelectric cell OMRON E3X NA41 Fiber optic OMRON E32 DC200 Electrical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 7 inputs 5 outputs Supply module 24V 60W PLC control CPU with digital inputs outputs Communication module for PLC n...

Page 73: ... of the turning mechanism The technology used to effect the movements at this module based on different pneumatic cylinders means it is only possible to unload the screws at a single point In consequence an additional component is needed for the transfer to give it successive turns so that four insertion cycles at this module will result in the four screws being fitted The components used for this...

Page 74: ... previous one This module inserts the screws into the holes of the body placed on the pallet after feeding and transfer by the previous module Figure 76 Manipulators of the twelfth module This operation begins when the pallet is positioned opposite the module held in a determined location by a stopper on the linear transfer and when the PLC of the eleventh module sends the signal end cycle to the ...

Page 75: ... parallel opening two finger gripper used to hold the screws Figure 77 Screws insertion manipulator TECHNICAL DATA Dimensions Table of slotted aluminium 450 x 600 mm Height 900 mm Air treatment unit Filter to 5 µm pressure regulator and pressure gauge Control panel Start stop reset pushbuttons Emergency stop button main switch on off mode selector auto man and error pilot indicator Composition of ...

Page 76: ...ing Two finger parallel opening pneumatic gripper MHK2 16D and open closed position detectors Controlled by 5 2 way bistable solenoid valve Sensors Reed type magnetic detectors D Z73L Electrical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 14 digital inputs 9 outputs Supply module 24V 60W PLC control CPU with digital inputs o...

Page 77: ...draulic technology was facilitated at the bearing pressing module With a view to matching the system to all the most widely used techniques in industrial automation this module introduces a new though widespread technology that of robotics Figure 78 FAS213 Robotized Screwing Module FUNCTION OF THE MODULE The operation carried out by the robot consists of tightening the four screws fitted to the bo...

Page 78: ...t accuracy controlling speeds accelerations and paths Figure 80 Arm for YASKAWA Figure 81 Compact controller for MOTOMAN robot YASKAWA MOTOMAN robot It is also possible to program the robot s movements into the controller and thereby specify what sequence of movements and commands has to be followed for a particular process Programming is carried out by means of specific software different dependi...

Page 79: ...at the pallet is in the correct position is provided by a microswitch which sends the appropriate signal to the PLC of the module which in turn sends the signal start cycle to the robot controller The positional accuracy enables the tip of the electric screwdriver to be located on each of the screws fitted in the body and then proceed to screwing Figure 83 Electrical screwdriver for YASKAWA MOTOMA...

Page 80: ...mpact Controller FS100 YASKAWA MOTOMAN Programming pendant YASKAWA MOTOMAN JZRCR YPP03 1 software and cable depending of the configuration Electrical Screwdriver Hitachi DB 3DL 3 6V y 180 rpm Electrical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 16 inputs 16 outputs Supply module 24V 60W PLC control CPU with digital inputs ...

Page 81: ...e the finished body is moved from the pallet retained at the transfer to an unloading point on a rotary positioning system inside the module The body is rotated to the first of two inspection positions and a Compact Colour Machine Vision System confirms the colour and the presence of the shaft the height the colour and the presence of the cover and the presence of the four screws with the first in...

Page 82: ...180º An arm is attached to the rotary actuator to move the turning mechanism into an unloading point placed over the rotary table This arm houses a mechanism consisting of a toothed belt and two pinions the purpose of which is to keep the pads orientation throughout the turning movement so that it can reach the inspection point in horizontal position The system of holding the body incorporates fou...

Page 83: ...ntioned the body is rotated to the first of two inspection positions and a vision camera confirms the colour and presence of the shaft the height the colour and the presence of the cover and the presence of two of the four screws The system is used with monitoring purposes based on an open loop concept Then it rotates to the second inspection position and the vision system confirms the presence of...

Page 84: ...lator Actuators Rotary actuator Double rack and pinion Ø50 max 180º MSQB50A with flow regulators and 0º 90º and 180º position detector Controlled by 5 3 way solenoid valve mid position closed Holding plate 4 suction cups Ø16 ZPT16UN B5 with ejector to generate vacuum ZU07S Controlled by 3 2 way biestable solenoid valve Sensors PNP type magnetic detectors D A93L Vacuum switch PNP output PS1100 R06L...

Page 85: ...ical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 15 digital inputs 15 outputs Supply module 24V 60W PLC control CPU with digital inputs outputs Communication module for PLC network connection ...

Page 86: ... depending of the signal about the vision inspection system from the PLC of the previous module This module after the checking of all the components of the assembly developed by the previous one according to the pattern will reject the assembly to a ramp if they are not correct The inspection operation is developed by the previous module If the inspection results are not good the turning mechanism...

Page 87: ...ed in an evacuation ramp of the module A two axis manipulator is used as handling device for this process to place the turning mechanism on the ramp Each axis is formed by a parallel rod cylinder The system of holding the body incorporates four suction cups vacuum pads which use an ejector produced vacuum to hold the assembly Figure 89 Rejection manipulator TECHNICAL DATA Dimensions Table of slott...

Page 88: ...end position detector Controlled by 5 2 way monostable solenoid valve Holding plate 4 suction cups Ø16 ZPT16CNK B5 A10 with ejector to generate vacuum ZU07S Controlled by 3 2 way biestable solenoid valve Sensors Reed type magnetic detectors D Z93L Reed type magnetic detectors D A93L Vacuum switch PNP output PS1100 R06L Electrical control panel Mounted on perforated mesh Accessible terminal plate w...

Page 89: ...MODULE Once the final assembly is completed it must be removed from the transport system This storage uses a system based on two coordinate axes so that the bodies with bearings shafts covers and screws picked off the conveyor belt may be allocated at any point on the surface of the module Figure 91 Manipulators of the storage module ...

Page 90: ...at its storage point Figure 92 Vertical axis Positioning axes The first operation consists of placing the vertical axis mentioned above over a fixed pick up point over the place where the pallet is stopped This operation is carried out by two shafts one of them is a pneumatic actuator and the other one is a positioning shaft driven by servomotor with absolute encoder to provide instantaneous readi...

Page 91: ... cylinder Ø20 Stroke 75mm CXSM20 75 with flow regulators and initial end position detectors Controlled by 5 2 way monostable solenoid valve Holding plate 4 suction cups Ø16 ZPT16CNK10 B5 A10 with vacuum generating ejector ZH10BS 06 06 Controlled by 3 2 way bistable solenoid valve Sensors Reed type magnetic detectors D Z73L Vacuum switch PNP output PS 1100 R06L X Y Positioning axes Actuators Double...

Page 92: ...EFS25AA 500 Electrical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 17 inputs 13 outputs Supply module 24V 240W Servodriver serie LEC PLC control CPU with digital inputs outputs Communication module for PLC network connection ...

Page 93: ...gure 94 FAS220 Pallet Transfer Module FUNCTION OF THE MODULE This modules allow transfer the pallets from one row of the system conveyor belts to the next one so when the layout of the system can be a closed loop or opened but never in line Figure 95 Manipulators of the pallet transfer module ...

Page 94: ...pened in U shaped there must be only one module FAS220 to transfer the pallets between the two linear transfers FAS230 Figure 96 System FAS200 in opened layout If the layout is closed in O shaped there must be two modules FAS220 to transfer the pallets between the two linear transfers FAS230 and close the way Figure 97 System FAS200 in closed layout ...

Page 95: ...al axis based on dual rod pneumatic cylinder The final handling is thanks to the vacuum system INTEGRAL PARTS The pallet transfer module like the others may be divided into a series of manipulators Each sub division has been made by considering it as a set of components which performs a specific operation within the whole process carried out at the module Vertical axis The system of holding the pa...

Page 96: ...ction cups final elements act with the vacuum Figure 100 Ejector and vacuum switch Horizontal axis The first operation consists of placing the vertical axis mentioned above over a fixed pick up point over the place where the pallet is stopped on the belts of the fist conveyor and transfer the assembly to the belts of the second conveyor This operation is carried out by a pneumatic cylinder a rodle...

Page 97: ... section 900 x 400 mm Height 900 mm Air treatment unit Filter to 5 µm pressure regulator and pressure gauge Control panel Start stop reset pushbuttons Emergency stop button main switch on off mode selector auto man and error pilot indicator Composition of module manipulators Vertical axis Actuators Double acting parallel rod cylinder Ø10 Stroke 50mm CXSM10 50 with flow regulators and initial end p...

Page 98: ...ectors Controlled by 5 2 way biestable solenoid valve Sensors Reed type magnetic detectors D Z73L Capacitive sensor OMRON E2K X4MF1 Electrical control panel Mounted on perforated mesh Accessible terminal plate with supply connections and coded I Os I O station 10 inputs 6 outputs Supply module 24V 60W PLC control CPU with digital inputs outputs Communication module for PLC network connection ...

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SMC Networks FAS-200, User Manual

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