Festo CP Factory User Manual

CP Factory®

Manual Robot feeding for mill

Festo Didactic CP Factory 12/2018

Order number: Status: 02/2018 Layout: 02/2018, Schober, Weiss File Name: CP-F-RASS-KUKA-GB-A001.doc

Intended use

This installation was developed and manufactured only for the 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 which may occur when the installation is used beyond a genuine training situation, except Festo Didactic has caused such injury or harm intentionally or by grossly negligence.

Experimenting on CP Factory / CP Lab systems with hazardous live voltage is not allowed.

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. 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.

Intended use also comprises observing all instructions in the operating manual and carrying out the inspection and maintenance works.

2 © Festo Didactic CP Factory ° Robot feeding for mill

Content

1 General safety instructions __________________________________________________________________ 6

1.1 Pictographs ___________________________________________________________________________ 7

1.2 Safety terminal sockets _________________________________________________________________ 8

1.3 Information for the electrical connection of the systems ______________________________________ 8

1.4 Handling the system ___________________________________________________________________ 9

1.4.1 Dangers when using the machine _____________________________________________________ 9

1.4.2 Safety precautions in normal operation ________________________________________________ 9

1.4.3 Dangers caused by electrical energy ___________________________________________________ 9

1.4.4 Dangers caused by pneumatic energy _________________________________________________ 9

1.4.5 Maintenance and fault clearance______________________________________________________ 9

1.4.6 Organizational measures ____________________________________________________________ 9

1.5 Staff ________________________________________________________________________________ 10

1.5.1 Instructions regarding the staff ______________________________________________________ 10

1.5.2 Training operations ________________________________________________________________ 10

1.5.3 Beyond training operations _________________________________________________________ 10

1.6 Commitment of the operator ____________________________________________________________ 10

1.7 Commitment of the trainees ____________________________________________________________ 10

2 Introduction _____________________________________________________________________________ 11

2.1 Warranty and liability __________________________________________________________________ 11

2.2 Important information _________________________________________________________________ 11

2.3 Resources ___________________________________________________________________________ 12

3 Design and function _______________________________________________________________________ 15

3.1 Transport ____________________________________________________________________________ 15

3.2 Set up ______________________________________________________________________________ 15

3.2.1 General notes ____________________________________________________________________ 15

3.3 Robot feeding for mill __________________________________________________________________ 16

3.3.1 General __________________________________________________________________________ 16

3.4 Mechanical structure __________________________________________________________________ 21

3.4.1 Supply of the Robot feeding for mill __________________________________________________ 25

3.5 Electrical set up ______________________________________________________________________ 27

3.5.1 Siemens PLC _____________________________________________________________________ 29

3.5.2 Cabling chart _____________________________________________________________________ 31

3.5.3 Emergency stop structure __________________________________________________________ 32

3.5.4 Emergency-stop with central control __________________________________________________ 35

3.6 Commissioning _______________________________________________________________________ 36

3.6.1 Pneumatic commissioning __________________________________________________________ 36

3.6.2 Electrical commissioning ___________________________________________________________ 36

3.7 Commissioning _______________________________________________________________________ 37

3.7.1 Pneumatic commissioning __________________________________________________________ 37

3.7.2 Electrical commissioning ___________________________________________________________ 37

3.8 Adjusting the sensors _________________________________________________________________ 38

3.8.1 Proximity switch (stopper Identsensor) _______________________________________________ 38

3.8.2 Proximity switch (stopper cylinder) ___________________________________________________ 40

3.9 Adjusting the one-way flow control valves _________________________________________________ 42

Content

3.10 Visual inspection ____________________________________________________________________ 43

3.11 Starting up _________________________________________________________________________ 43

4 Operation _______________________________________________________________________________ 44

4.1 General notes on operation _____________________________________________________________ 44

4.1.1 Handling regulations ______________________________________________________________ 44

4.1.2 Operating regulations ______________________________________________________________ 44

4.2 The control units of the robot feeding for mill ______________________________________________ 45

4.2.1 Touch Panel ______________________________________________________________________ 46

4.3 Sequence description of robot feeding for mill _____________________________________________ 47

4.4 Sequence description of the Basic Module ByPass _________________________________________ 49

4.4.1 CP Factory Loading Robot (Mill and Turn) ______________________________________________ 54

4.4.2 Switch on robot ___________________________________________________________________ 57

4.5 Operating modes _____________________________________________________________________ 58

4.5.1 Automatic operation _______________________________________________________________ 58

4.5.2 Setup mode ______________________________________________________________________ 58

4.6 Operating the HMi Touchpanel __________________________________________________________ 58

4.6.1 Menu architecture from Panel _______________________________________________________ 59

4.6.2 Menu navigation robot feeding for mill ________________________________________________ 60

4.6.3 Display operation modus ___________________________________________________________ 62

4.6.4 Operation mode Home _____________________________________________________________ 63

4.6.5 Operating mode Setup _____________________________________________________________ 69

4.6.6 Operation mode Parameters ________________________________________________________ 76

4.6.7 Operation mode System - settings ___________________________________________________ 80

4.7 Automatic operation __________________________________________________________________ 81

4.7.1 Start automatic ___________________________________________________________________ 81

4.7.2 Stop automatic ___________________________________________________________________ 83

4.8 Writing on the RFID tag manually ________________________________________________________ 84

4.8.1 Pallet carriers ____________________________________________________________________ 84

4.8.2 Boxes ___________________________________________________________________________ 86

4.8.3 Parameter CP Factory feeding robot and mill ___________________________________________ 87

5 Components _____________________________________________________________________________ 88

5.1 Mitsubishi Robot RV-4FL _______________________________________________________________ 88

5.1.1 Drive Unit CR750-D ________________________________________________________________ 89

5.1.2 Teach pendant R32TB ______________________________________________________________ 91

5.1.3 Teachpendant R56TB ______________________________________________________________ 92

5.1.4 Set up ___________________________________________________________________________ 93

5.1.5 Interface Drive Unit ________________________________________________________________ 96

5.1.6 Parameter ______________________________________________________________________ 100

5.1.7 Main tasks/Programmes __________________________________________________________ 101

5.1.8 Return message _________________________________________________________________ 101

5.1.9 Further information to robot _______________________________________________________ 101

5.2 Robot positions _____________________________________________________________________ 102

5.3 Electrical components ________________________________________________________________ 103

5.3.1 2 Quadrant Controller _____________________________________________________________ 103

5.3.2 Controller Siemens _______________________________________________________________ 106

5.3.3 Controller Festo CECC _____________________________________________________________ 107

5.3.4 Turck Interface___________________________________________________________________ 108

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Content

5.3.5 Scalance Ethernet Switch __________________________________________________________ 109

5.3.6 RFID with Ethernet _______________________________________________________________ 112

5.3.7 RFID with CanBus ________________________________________________________________ 116

5.3.8 Mini Terminal ____________________________________________________________________ 117

5.3.9 SYS link interface ________________________________________________________________ 121

5.4 Mechanic components ________________________________________________________________ 122

5.4.1 Motor of Conveyor _______________________________________________________________ 122

5.4.2 The stopper unit _________________________________________________________________ 123

5.4.3 Transportation of the basic module _________________________________________________ 125

General safety instructions

1 General safety instructions

The laboratory resp. the classroom must be equipped according to the rules of EN 50191:

 There must be Emergency Stop equipment in the training area and at least one Emergency Stop outside

the training area.

 The training area must be protected against any unauthorized switching-on, e.g. by key-operated

switches.

 The training area must be protected by fault current protective circuit (RCD).

– RCD circuit breaker with differential current ≤ 30 mA, type B.

 The training area must be protected by overcurrent protections -

– fuses or circuit breakers

 The training area must be supervised by a person who is responsible for the activities.

– This person must be a skilled electrician or a person instructed in electrical engineering with the knowledge of all safety requirements and safety precautions on file.

 Any damaged device or faulty device may not be used.

– Any faulty or damaged device has to be blocked and removed from the training area.

General requirements regarding a safe operation of the devices:

 Do not lay cables over hot surfaces.

– Hot surfaces are marked with a corresponding warning symbol.

 The permitted power loads of cables and devices may not be exceeded.

– Do always compare the current values of the device, the cable and the fuse. – In case of non-compliance, you have to use a separate upstream fuse as an appropriate overcurrent

protection.

 Any device with earth connection must always be grounded.

– If there is a ground connection (green-yellow laboratory socket) available, the connection to the protective ground must always be effected. The protective ground must always be contacted first (before voltage) and must only be separated last (after voltage separation).

 If not specified differently in the technical data, the device does not have an integrated fuse.

6 © Festo Didactic CP Factory ° Robot feeding for mill

General safety instructions

Warning This means that in case of disregarding the rules, serious personal injury or material damage may occur.

Caution This means that in case of disregarding the rules, personal injury or material damage may occur.

Warning This means that prior to any mounting, repair, maintenance or cleaning operations, you have to switch off the device and to disconnect the power plug. Please observe the manual, especially all information on safety. In case of disregarding, serious personal injury or material damage may occur.

Warning This means that you could burn yourself when touching hot surfaces (temperatures up to 85 ° Celsius).

Important Here you find important information for an appropriate handling of the machine. Disregarding this symbol may lead to malfunctions at the machine or in its surrounding area.

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Information This means that you obtain tips for the use and especially useful information.

1.1 Pictographs

This document and the described hardware contain information on possible dangers which may occur when using the system improperly. The following pictographs are used:

General safety instructions

Colour

Meaning

Colour

Meaning

Voltage bigger protective low voltage, e.g. supply voltage 90 to 400 V AC conductor (grey)

24 V DC (red)

neutral conductor (grey/blue)

0 V DC (blue)

protective earth conductor (green-yellow)

protective low voltage signal input/signal output (black)

Any damaged or faulty safety laboratory cables have to be blocked instantly and to be removed from the training area.

1.2 Safety terminal sockets

If not specified differently in the technical data, the following colour coding applies for the power and signal supplies with components of the FESTO Didactic learning system automation and technics.

The specified protection categories and the safety can only been guaranteed when using Festo Didactic safety laboratory cables.

1.3 Information for the electrical connection of the systems

For the supply of the CP-Factory/ CP-Lab systems, according to the regulations of the EN 60204-1 (VDE 0113-1) part 8.2.8, a supply cable with an additional protective earth conductor is required. Since a leakage current of > 10mA may flow depending on the expansion, an additional protective earth conductor with 10mm² is required.

See also DIN EN 60204-1.

8 © Festo Didactic CP Factory ° Robot feeding for mill

General safety instructions

Any faults which might affect the safety must be eliminated instantly!

1.4 Handling the system

1.4.1 Dangers when using the machine

The system has been constructed in accordance with the state of the art and the recognized safety rules. Nevertheless, there might occur dangers to life and limb of the user or a third person when used, as well as negative impact on the system or on other material assets.

You may only use the system:

 for the intended use  in excellent condition concerning safety regulations

1.4.2 Safety precautions in normal operation

Please use the system only if all safety devices are fully functional. Please inspect the system regarding externally discernible damages and the functionality of the safety devices at least before starting the operation. Do not touch the running station. Before any circuit assembly, disassembly or modifications in a circuit: Switch off the compressed air supply and the power supply. Observe the general safety regulations: DIN 58126 and VDE 0100.

1.4.3 Dangers caused by electrical energy

After finishing the maintenance works you have to check the safety devices regarding their function. Only an electrically or electronically trained person is allowed to execute operations on the electrical supply. The terminal boxes have to be kept close all of the time. Any access is only allowed if supervised by a training person. Please do not operate electrical limit switches manually when searching for an error, but use the tools. Please do only use low voltage 24 VDC.

1.4.4 Dangers caused by pneumatic energy

Tubes coming off due to compressed air may cause injuries. Take away the pressure instantly. Caution! When switching on the compressed air, the cylinders may drive in or out automatically. Do not uncouple the tubes when under pressure. Exception: Debugging. In this case, you have to hold the tube end tight. Do not exceed the permitted working pressure. See also data sheets.

1.4.5 Maintenance and fault clearance

Carry out all prescribed setting and servicing work in due time (see data sheets). Protect the compressed air and the electrics against an accidental commissioning. During all maintenance, servicing or repair works, the machine must be disconnected from the power supply and the compressed air supply, and it must be protected against an unintentional restart. Please check that all screw connections which have been loosened during the maintenance, servicing or repair works are firmly seated.

1.4.6 Organizational measures

All existing safety equipment has to be checked regularly.

General safety instructions

1.5 Staff

1.5.1 Instructions regarding the staff

Regarding the staff, there are basically two starting situations to be considered.

 activities during the training operation  activities not connected with the training operations.

1.5.2 Training operations

The trainees are only allowed to work on the machine if supervised by a skilled person or the instructor. Any activities concerning fault finding and elimination are controlled by the instructing person. Safety regulations have to be observed here in particular.

1.5.3 Beyond training operations

All activities concerning maintenance, servicing and repair may only be executed by a person with sufficiently professional qualifications.

1.6 Commitment of the operator

The operators commit themselves to only allowing the work at the CP-Factory/ CP-Lab to a person who:

 is familiar with the principle directions of work safety and accident prevention and has been instructed

in the handling of the CP-Factory / CP-Lab,

 has read and understood the safety chapter and the warnings in this manual.

The safety-conscious working of the staff should be checked at regular intervals.

1.7 Commitment of the trainees

Before they start work, all persons in charge of works at the system commit themselves to:

 read the safety chapter and the warnings in this manual,  observe the basic principles about work safety and accident prevention.

10 © Festo Didactic CP Factory ° Robot feeding for mill

Introduction

2 Introduction

2.1 Warranty and liability

Basically, our “General Terms and Conditions“ apply, which have been made available for the user since the conclusion of the contract at the latest. Any warranty and liability claims for personal or material damage will be excluded, if they result from one or more of the following causes:

 any non-intended use of the system  any improper mounting, commissioning, operating and servicing of the system  any operating of the system with faulty safety devices or safety and protective devices which have not

been mounted properly or are not functioning

 any disregarding of the information in the manual concerning transport, storage, mounting,

commissioning, operation, servicing and setting-up of the system

 any unauthorized constructional alterations on the system  insufficient monitoring of installation parts which are subject to wear and tear  any improperly executed repairs  any major emergencies caused by external influence and force majeure.

Festo Didactic herewith rules out any legal responsibility for damages of the trainee, the training company and/or a third party which might occur when using the system beyond a genuine training situation, unless the damage has been caused by Festo Didactic intentionally or due to gross negligence.

2.2 Important information

Knowing the basic safety instructions and the safety rules is a basic prerequisite for the safe handling and the trouble-free operation of the system. This manual contains the most important information in order to operate the system in a way that meets the safety demands. The safety instructions in particular have to be observed by any person working with the system. Furthermore all rules and instructions concerning accident prevention applying to the deployment location have to be observed.

Introduction

2.3 Resources

The training equipment of the system consists of several resources. They are used depending on the process selection. The following resources are available:

Pallet carrier

These pallet carriers are available for transporting the pallets.

Pallet

These pallets are available for receiving always one workpiece.

12 © Festo Didactic CP Factory ° Robot feeding for mill

Introduction

Box with retainer for 2 pallet carriers – Box Partnumber 20

Box with retainer for 15 raw turning pieces – Box Partnumber 26

Box with retainer for 10 PCB´s – Box Partnumber 27

Box with retainer for 10 front/backcovers or assembled workpieces – Box Partnumber 28

Introduction

Workpieces

Description

CP back cover

no 111

CP board no 120

CP fuse no 130

CP front cover

no 210 - if there is a CNC milling machine integrated in the system, the front cover can also be produced there , thus becoming a production part.

Workpieces

Description

Workpieces

Description

CP no fuse

no 211

CP part no fuse

no 1211

CP fuse on the left

No. 212

CP part fuse on the left

No. 1212

CP fuse on the right

no 213

CP part fuse on the right

no 1213

CP fuses both

no 214

CP part both fuses

no 1214

CP part customer

no 1210 freely selectable

External production parts

Production parts

14 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

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Warning Before the transport, all supply roads must be cleared to be passable for the industrial truck. If necessary, you have to install warning signs or barrier tapes. When opening the transport boxes you have to be very careful because additional components like computers may also be delivered with the box and have to be protected against dropping out.

Caution

If the transport box is opened and the possibly additional components are taken out, you can remove the station and bring it to its place of destination. Please check the stability of all profile connectors with an Allen key size 4-6. It might happen that the connectors are loosened during the transport due to inevitable vibrations. Please pay special attention to any protruding components, sensors or other small parts may easily be damaged during an improper transport. Do not grab the station at or even under the pedestals – high risk of being crushed or jammed!

3 Design and function

3.1 Transport

On delivery of the stations, special attention must be payed on transporting them only by a suitable industrial truck. The weight of a station may amount up to 500 kg.

3.2 Set up

3.2.1 General notes

You have to install the system in a frost-free room with a maximum relative humidity of 70 % and a maximum ambient temperature of 25 ° Celsius. In countries with a higher humidity or higher temperatures, you have to install air-conditioning systems for constant ambient conditions. You first have to check any electrical disturbing sources like welding systems, big motors and contactors regarding their EMC and if necessary to shield them in order to obtain the values permitted in the guidelines. A stable ground is essential for a trouble-free operation in order to avoid subsidences. You have to see for an appropriate distance between the system and the wall. Keep away any dust from the station resulting from construction works (covering).

Design and function

3.3 Robot feeding for mill

3.3.1 General

The robot feeding for mill consists of a basic module bypass and a loading cell with robot as well as the CNC machine. The conveyor belts have a width of 80 mm and a length of 1200mm. Carriers with workpieces can be removed and transferred here for a longer processing. Thus, applications with a longer processing time can be mounted on the bypass. The workpiece flow is not affected by the bypass line. The conveyors are for transporting boards on carriers. The carriers are equipped with a read/write IDsystem. This ID-system represents an important item of the CP Factory System. Current data of the workpiece to be transported is written on the carriers. Thus all information essential for the process is transported together with the carrier and is therefore available at every station.

On bypass module an aluminum plate is mounted on a base frame. On this plate is a 6-axis robot and the associated periphery. The robot is responsible for handling all processes within the module. For machining the workpieces, a CNC machine is mounted on the base frame. The task of the station is to equip the CNC milling machine with workpieces and to process the workpieces according to the requirements in the CNC machine.

Different types of robots can be mounted, should there be differences in handling or the interfaces, this is indicated separately in the operating instructions.

16 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

Position

Description

1

CNC milling machine

2

Feeding robot for mill

3

Basic module bypass

Design and function

CP Factory robot feeding for mill – front side

18 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

Position

Description

1

CNC machine

2

Robot

3

Conveyor

4

Working position / workpiece carrier output slide

5

Main switch operation panel

6

Touchpanel

7

E-Board for basic module bypass

8

Multi contact plug

9

Pressure switch (option for energy monitoring) and RFID

10

removable corner pulley /other module available

11

Emergency stop

12

Passage for power supply

Design and function

Position

Description

1

E-Board application

2

Drive Unit

CP Factory robot feeding for mill – back side

20 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

3.4 Mechanical structure

The robot feeding for mill is designed for one-sided operation (1). The module is equipped with mechanically adjustable feet. Should it be necessary to move the module to another place, it can be lowered to its rollers and thus be transported easily.

Design and function

Position

Description

1

Operation as independent Basic Module /not put together

2

Operation as independent Basic Module /Basic Module put together

3

Operation connected with another Basic Module

The modules can be operated in two ways - as a single station or in a chain with further modules. When connected to a further module, it is necessary to replace the deflection at the end of the band by means of a support plate. The switch is an exception, if this is operated as a single station, it is not possible to eject or introduce workpieces via the switches.

Installation Options example

With the pluggable tape deflections there are different possibilities to control the transport flow. Depending on this, different modules can be operated individually or in combination.

22 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

Position

Description

1+2

corner pulley – the pallet carrier is reversed from one conveyor to the other on the Basic Module ByPass

Installation as independent module

Design and function

Position

Description

1

Replacement guide board (support plate) if connected to another module – the pallet carrier is not reversed but directed to the next module

2

corner pulley – the pallet carrier is reversed from one conveyor to the other conveyor on the Basic Module ByPass

Installation in combination with an Basic Module linear

The corner pulley and the support plate are only pinned and can be changed easily without tools.

24 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

Position

Description

1

Inlet port for connection tube with voltage, communication and pneumatics

2

Connection plug K2-XZ1

3

Connection plug K2-XZ2

4

Outlet port for the connection tube of a further module

3.4.1 Supply of the Robot feeding for mill

CP Factory supply

Design and function

Position

Description

1

Emergency chain linking

2

Pressure

3

Network

4

400 V

26 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

3.5 Electrical set up

The robot feeding for mill has two electric boards. The main electric board is mounted on the front of the base frame and is responsible for the conveyor belt with the bypass. The electric board for the feeding is mounted on the back. The drive unit for the robot is also located on the back of the base frame.

E- Board robot feeding for mill front side

Design and function

E-Board robot feeding for mill back side

28 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

Position

Description

BMK

Description / Ordernumber

1

Power supply 24 V

K1-TB1

Festo CACN-3A-1-10 / 2247682

2

Emergency stop distributor

K1-F2-XZ2

3 Emergency stop unit

K1-F2-KF1

Siemens / 3SK1111-2AB30

4

Fuses

Han 10A-asg2-LB-M20

5

Harting plug

K1-FC1 + K1-FC2

6 protective contact socket 230 V

K1-XJ4

7 ELEC AUX CIRCUIT

K1-FC4

Murr Elektronik / 9000-41042-0100600

8

Clamps

K1 XD0-K1-XD13

9 PLC

K5-KF1

ET 200 SP CPU 1512SP F-1 P

10

I/O terminal

K1-XD15

11

Start-up current limiters

K1-QA1

Kaleja M-MZS-4-30 / 06.05.020

12

Start-up current limiters

K1-QA2

Kaleja M-MZS-4-30 / 06.05.020

13

Start-up current limiters

K1-QA3

Kaleja M-MZS-4-30 / 06.05.020

14

Ethernet Switch

K1-XF1

Siemens Scalance XB008 / 6GK5008-OBAOO-1AB2

3.5.1 Siemens PLC

E-Board front side conveyor with bypass

Design and function

Position

Description

BMK 1 Clamps for power distribution

XD1 / XD10

2

Pilz PSEN iX1

F2-KF3

3

Emergency stop unit PNOZ X8P

F2-KF2

4

Harting plug

XJ4 5 protective contact socket 230 V

XD3 6 protective contact socket 230 V

K6-XD6

7

MIT-SUP-EL20-ER-6

K6-KF2

E-Board back side robot feeding for mill

30 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

3.5.2 Cabling chart

Overview cabling chart Mitsubishi / Siemens

Design and function

Position

Name

1

Safety door / -H1-F2-FQ3

2

Safety door / -H1-F2-FQ2

3

Safety door / -H1-F2-FQ4

4

Safety door / -H1-F2-FQ1

5

Emergency stop switch F2-FQ1 / to emergency stop board X4:1: X4:3; X4:5; X4:7

6

Reset button SF2 / to PNOZ S33+S34; lamp clamp 24VNA/0V+

7

Emergency stop board for emergency stop linking / F2-XZ2

8

Emergency stop unit / F2-KF1

9

Drive Unit / K6-KF1

10

PSEN iX1 / F2-KF3

11

PNOZ X8P / F2-KF2

3.5.3 Emergency stop structure

The emergency stop components on the back side are firmly wired to the front. The type of control does not matter.

32 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

Board Emergency-Stop interconnection

F2-XZ2-X1 Emergency-stop coupling input / If there is no previous station, you have to attach a bypass plug here or at the system plug.

F2-XZ2-X2 Emergency-stop coupling output 1 / If there is no subsequent station, you have to attach a bypass plug here or at the system plug.

F2-XZ2-X3 Emergency-stop coupling output 2 / for the connection of a further module or an external machine (e.g. for the basic module shunt – another module can be placed here at the junction, or a CNC processing machine, for example, can be placed at a bypass), otherwise you have to attach a bypass plug.

F2-XZ2-X4 Terminal clips for control panel, power supply, Emergency-stop relay.

Example for Emergency-stop linking with 3 modules

Design and function

Enabling the Emergency-stop

If the Emergency-stop button has been pressed, a fault is indicated at the HMi. If you click on the message line at the top, the fault will be indicated in the main window.

1. The emergency-stop situation is indicated in the message line. If you click on this line, the message will

appear in the main window.

2. Display of the emergency-stop situation.

3. When the emergency-stop situation is eliminated, you have to disconnect the emergency-stop

pushbutton. Then you have to press the blue illuminated pushbutton “Adjusting”. Now you can

acknowledge the message by pressing the button at the HMI. The module can now be restarted.

4. If the module has been connected with other modules, the emergency-stop is effective at all stations

and must therefore be acknowledged at every station by pressing the illuminated push-button “Adjusting” and acknowledging the error at the HMi

34 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

3.5.4 Emergency-stop with central control

Structure of the emergency-stop system

At the central emergency-stop (power cabinet), a central emergency-stop control unit PNOZ-X8P is connected with one of the modules. The connection to one of the modules is effected by the energy supply.

Enabling the emergency-stop

If the emergency-stop has been pressed at any station, an error message is displayed at every HMI. First you have to find out the station where the emergency-stop has been pressed. At this module, you can click on the message line at the top at the HMI, where the error message will be displayed in the main window.

Design and function

1. Emergency-stop situation is displayed in the message line. If you click on the line, the message will

appear in the main window.

2. Display of the emergency-stop situation.

3. If the emergency-stop situation has been eliminated, you have to disconnect the emergency-stop

pushbutton. After that, you have to press the blue illuminated pushbutton “adjusting”. Now you can acknowledge the message by pressing the button at the HMI. The module can now be re-started. The emergency-stop is effective at every station, therefore it has to be acknowledged at every station at the HMI with the illuminated pushbutton “adjusting” and by acknowledging the error at the HMI.

3.6 Commissioning

The module has got several components which have to be connected on commissioning. The procedure will be described in the following chapters.

3.6.1 Pneumatic commissioning

The mechanic assembly must be finished. First you have to connect the module to the pneumatic system of the room. The service unit required has to be provided by the customer and should be within close proximity. The quick coupling plug has got a nominal size of 5 mm. If the respective system is equipped with

7.9 mm nominal size it will be possible to exchange the coupling plug of the service unit by a bigger one (adapter 1/8 to 1/4 required). Then the station can be supplied with 6 bar and the pneumatic commissioning is finished.

3.6.2 Electrical commissioning

Now the module must be supplied with electric voltage (400 V). The voltage has to be provided by the customer. Furthermore, an expert installation must be guaranteed.

36 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

3.7 Commissioning

The robot feeding for mill has got several components which have to be attached when starting up. The procedure will be described on the following pages.

3.7.1 Pneumatic commissioning

The mechanic mounting must be finished and completed. At first you have to connect the robot feeding for mill to the pneumatic system of the room. The corresponding service unit has to be provided by the customer and should be placed right next to it. The quick coupling plug has got a nominal size of 5 mm. If the local system has got a nominal size of 7.9 mm, it is possible to exchange the quick coupling plug of the service unit for a bigger one (adapter 1/8 to 1/4 necessary). Now the station can be supplied by 6 Bar and the pneumatic commissioning is completed.

3.7.2 Electrical commissioning

Now the robot feeding for mill has to be supplied with electric voltage (400 V). The voltage has to be provided by the customer. Professional installation must be guaranteed as well.

Design and function

Position

Description

1

Sensor stopper identify sensor / 150395 (SIEN-M8NB-PS-S-L) 1 position (BG21/BG31/BG41) 2 position (BG22/BG32/BG42) 3 position (BG23/BG33/BG43) 4 position (BG24/BG34/BG44)

2

Screw to clamp the sensor

3.8 Adjusting the sensors

3.8.1 Proximity switch (stopper Identsensor)

The proximity switches are used for controlling the pallet.

38 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

Requirements

– Stopper unit is attached to the conveyor. – Electrical connection of the proximity switches is set up. – Power supply is available.

Procedure

1. The stopper is in upper position, a pallet is stopped at the stopper.

2. Shift the switch as long as the switching status display (LED) appears.

3. Shift the proximity switch into the same direction by a few millimetres as long as the switching status

display disappears.

4. Shift the proximity switch halfway between the start-up and end position.

5. Tighten the locking screw of the proximity switch with an Allen key SW 1,3.

6. Check the position of the proximity switch by repeated removing the pallet.

Documents

 Data sheets / operating instructions

Proximity Switch 150395 (SIEN-M8NB-PS-S-L)

Design and function

Position

Description

1

Sensor stopper down/ 574334 (SMT-8M-A-PS-24V-E-0,3-M8D) (BG20) / (BG30) / (BG30) / (BG40)

3.8.2 Proximity switch (stopper cylinder)

The proximity switches are used for controlling the end position of the cylinder for the stopper. The proximity switches react to a permanent magnet on the piston of the cylinder.

40 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

Requirements

– Cylinder stopper is attached to the conveyor. – Pneumatic port of the cylinder is set up. – Compressed air supply is switched on. – Electrical connection of the proximity switches is set up. – Power supply is available.

Procedure

1. The cylinder is in its end position to be queried.

2. Shift the proximity switch as long as the switching status display (LED) appears.

3. Shift the proximity switch into the same direction by a few millimetres as long as the switching status

display disappears.

4. Shift the proximity switch halfway between the start-up and end position.

5. Tighten the locking screw of the proximity switch with an Allen key SW 1,3.

6. Check the position of the proximity switch by repeated test runs of the cylinder.

Documents

 Data sheets / operating instructions

Proximity Switch 574334 (SMT-8M-A-PS-24V-E-0,3-M8D)

Design and function

Pos

Description

1

One-way flow control valves GRLA for stopper cylinder

2

One-way flow control valves GRLA for stopper cylinder

3.9 Adjusting the one-way flow control valves

One-way flow control valves

42 © Festo Didactic CP Factory ° Robot feeding for mill

Design and function

One-way flow control valves are used for the regulation of the exhaust air volume of double-acting drive units. In the opposite direction the air flows through the flow control valve having a full cross-sectional flow. The piston is clamped between air cushions by free supply air and throttled exhaust air (improvement of the operating behaviour even if the load changes).

Requirements

– Pneumatic port of the cylinders is set up. – Compressed air supply is switched on.

Procedure

1. At first, turn off both one-way control valves completely. Then turn them on by about one rotation.

2. Start a test run.

3. Turn on the one-way flow control valves slowly as long as the required piston speed has been reached.

Documents

 Data sheets

One-way flow control valve (193138)

3.10 Visual inspection

Visual inspection must always be done before starting up! Before starting the station, please check:

 the electrical connections  the correct fit and condition of the supply ports  the mechanic components regarding visible faults (cracks, loose connections etc.)  the function of the Emergency Stop

Please make sure that all damages discovered are removed before starting the station!

3.11 Starting up

For the robot feeding for mill, an „initial start-up“ has already been conducted. In order to be able to work with the basic modules and the applications, you have to carry out the following measures:

1. You have to provide the mains supply 400 V AC for the module.

2. The robot feeding for mill is supplied by about 6 bar compressed air. On initial start-up, please pay

attention to slowly increasing the pressure (herewith unpredictable events are prevented).

3. Now you can work with the module.

Operation

4 Operation

The chapter Operation describes the control units required for the operation, as well as start-up and closedown of the system.

4.1 General notes on operation

The stations demand strict adherence to certain rules of operation. Negligence in observing these rules may cause errors in the stations’ processes. Also, damage to physical health cannot be excluded. Strict observance of the following rules is demanded.

4.1.1 Handling regulations

 Manual interference during the stations’ operation is prohibited.  In case of larger audience, a mechanical barrier of the station is required.  It is prohibited to pull off any cables while voltage supply is not deactivated.  Any kind of liquid is to be kept from the installation, at all times.

4.1.2 Operating regulations

The stations are to be operated only from trained personnel. Operation is to ensue according to operating instructions. Uncontrolled pressing of the various switches/push-buttons of the control units is to be omitted / prevented. No work-piece carriers should to be removed from the system.

44 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Position

Description

1

Main switch -QB1

2

Manometer

3

Touch Panel – PH1

4

Emergency- stop switch – F2-FQ1

5

Network socket- XPN3

6

Controller on pushbutton – F2-SF1

4.2 The control units of the robot feeding for mill

CP Factory control panel front side

Operation

4.2.1 Touch Panel

Siemens TP 700 Comfort

Supply voltage

Type of supply voltage DC Rated value (DC) 24 V permissible range, lower limit (DC) 19.2 V permissible range, upper limit (DC) 28.8 V

Input current

Current consumption (rated value) 0.5 A Starting current inrush I²t 0.5 A²·s

Power

Power consumption, typ. 12 W

Processor

Processor type X86

Memory

Flash Yes RAM Yes

Memory available for user data 12 Mbyte

46 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

4.3 Sequence description of robot feeding for mill

Reset sequence

Operation

Automatic sequence

48 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Position

Description

1

Stopper in bypass

2

Stopper without RFID

3

Branch

6

Stopper branch bypass

4.4 Sequence description of the Basic Module ByPass

Operation

Sequence description bypass

stopper without RFID

50 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Automatic stopper in bypass area

Operation

Bypass bend off

52 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Bypass straight

Operation

4.4.1 CP Factory Loading Robot (Mill and Turn)

1. All EMERGENCY STOP signal transmitters (push buttons, door contact, light barriers, etc.) are not

activated or activated and unlocked.

2. Remove any existing workpieces from the clamping unit.

3. Switch on the main switch

4. Alignment button lights up blue, HMI is started and starts up

5. Switch on and start the PC of the CNC machine

6. If the automatic mode has already been started on the HMI, the DNC tool or the EMCO keyboard must

no longer be directed. The straightening process is carried out automatically in this case.

7. Start DNC Tool on Windows

The program is not displayed in the Windows taskbar, but can be reached via the "hidden icons" tray).

8. If the DNC Tool is started, the following connections must exist

Connected to EMCO - lights up green when connected to the CNC, otherwise yellow (1) Connected to MES - lights up red because there is no direct connection from MES to the PC of the CNC machine (2) Connected to PLC -lights green if connection to PLC already exists, otherwise yellow (3)

9. The DNC connection must be displayed on the EMCO software. If this is not the case, the connection has

to be re-established. (4)

10. Select the function "HMI operate Mill" from the Emco display and confirm with OK

11. There are two ways to align the CNC machine, either with

the keyboard of the CNC machine * or via the DNC Tool **.

12. Now align the robot straightening and the key switch on the TeachBox into the horizontal position

13. Select T1 mode

14. Set the key switch vertically

15. Delete error messages with Confirm

16. On the right-hand side of the Teachbox, select "Cell"

54 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

17. Select "Select" in the lower section

18. Lightly press the right or left safety switch on the back of the Teachbox until A1-A6 is green

19. Select Program No. 5

20. Press the arrow key to the right

21. Display jumps to program 8

22. Press the right arrow key again

23. Display jumps to program 9

24. Set the key switch horizontally

25. Select the "EXT" key

26. Set the key switch vertically

* Reset CNC machine with DNC Tool

 Close the door (6)  Referencing (4)  Enter program 999 (5)  Load the program (1)  Start the program (2)  Open clamping device if this is not done automatically (3)

** Adjust the CNC machine with the Emco keyboard

1. Turn the left rotary switch for the operating mode on the CNC keyboard to the "Reference mode"

position.

2. Turn the right rotary speed switch on the CNC keyboard to 20%

3. Close the door using this button.

Operation

4. Close the clamping device

5. Press the reference key, the CNC machine executes reference move and the key lights up

6. Now the speed can be increased to 100% with the rotary switch

7. When the reference run is completed, the reference button doesn’t lights up anymore

8. Rotate the left rotary switch for the operating mode on the CNC keyboard to the following position

9. Now press the right mouse button on one of the lower fields or press the "Program" button on the

Sinumerik control to open the program selection

10. Select a program e.g. Program 20

11. Press the Green Start button

12. Open the clamping device

13. Confirm any HMI error messages displayed

56 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Should it be necessary to open the doors of the module, please make sure that these doors are equipped with a safety switch. To prevent the robot from being placed in an emergency stop situation, it is necessary to set the key switch to the manual position on the drive unit. The robot is now in TeachMode and the doors can be opened. Be very careful with the doors open, making sure that the robot does not move. When the doors are closed again, the reset process must be carried out again.

4.4.2 Switch on robot

1. Switch on the drive unit of the robot.

2. Switch on the TeachBox of the robot

3. It is important to keep the working area of the robot free!

4. The reset process is carried out via the touch panel on the basic module bypass.

5. Unlock the emergency stop button.

6. Press the reset button.

Operation

4.5 Operating modes

4.5.1 Automatic operation

 MES mode

In the MES mode, all processes are centrally started, executed and monitored by the MES software. All stations must be set to MES mode and automatic start.

 Default Mode

The automatic sequence is not centrally controlled in the default mode, all information from the transition tables (see chapter "Schematic process flow") is read and processed separately at each station.

4.5.2 Setup mode

In setup mode, all sensors can be displayed and actuators can be controlled from the HMI. This is used for troubleshooting or commissioning.

4.6 Operating the HMi Touchpanel

The operation on the basic modules is always the same. A basic module with the drilling module application module serves as an example. Additional operating options are described separately in the respective manuals. The operation is not dependent on the type of the control panel, Festo and Siemens Panel have the same functions.

58 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Position

Description

1

Description of menu (main or submenu) OR in case of an active Error or an error message, this field is also for announcement

2

Main menu (always shown the same)

Operating mode Home: Here the module can be controlled, the mode (default / MES) can be selected, the automatic or the set-up mode can also be operated.

Operating mode Setup: Here, the application can be operated manually in setup mode

Operating mode Parameter: The parameters of the application are set here, a simulation can be started, the transitions can be defined, or the tape can be set

System type: Here the system parameters such as language, time, etc. are set

3

Submenu in the main menu Changing content, depending on the main menu

4

Changing content, depending on the main or submenu

5

Announcement of operation mode automatic or set up

6

Announcement of default or MES Mode

4.6.1 Menu architecture from Panel

Operation

4.6.2 Menu navigation robot feeding for mill

General operation notice

 White buttons with blue letters – function is active  White buttons with black letters – function is not active  Blue buttons – function is active – waiting for insert  Grey buttons with grey letters – function not available at the moment  Grey buttons with blue letters – function can be executed  Green advice – Sensor/function is active  Orange device – announce an actor

Blue “Connect” button - active if the robot is connected to the PLC Blue “StartPrg” button - is blue until a program is running “StartPrg” button - the robot makes the program which is define in the “byPrograNum” parameter

 By default the byStopperPos is a constant and equal to 1, because there is no other position is defined

(this should be changed from the PLC program)

 “xExitCycle” is exit from the actual program which is running  xRetryCycle” retries the actual state of the program  “ClearError” reset the connection and state of the PLC (not resetting the return value, that is handle by

the robot)

 In setup mode there is no interactive message in case of a return value appears  In automatic in case of an error, an interactive message window appears with the Exit and Retry buttons  In case the door is opened a warning message appears in the top of the screen with yellow background:

“Safety doors opened”

 If the robot controller is not in manual mode, the PLC recognize this as well as “Safety doors opened”  The doors can be opened while the robot is running. In this case there is no interactive error message,

only the yellow warning message. The robot stops, until the doors are opened. After closing them, the robot keep continues its actual task

60 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Position

Description

1

If you click on the blue marked field (no matter where you are in the menu), the following window will open (Pos 2)

2

Operating window – the operating window is always the same and allows a fast operating of the station

Operation

4.6.3 Display operation modus

In the Home operating mode on the Overview page, different states can be displayed depending on the mode (MES or Default).

In the upper right-hand area, the order data of the workpiece carrier are displayed in the MES mode, while the RFID status code is displayed in the default mode. The status of the application is displayed in the lower right area, which is independent of the selected mode.

62 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Position

Description

1

Reset Button

2

Automatic Button: An automatic sequence is started depending on the mode (Default / MES)

3

Setup button: Here the application module can be controlled manually and sensors can be displayed. To put an application module into operation or suitable for troubleshooting. There is no difference in the mode - the setup mode is independent of the default or MES mode.

4

End Button: The currently active operating mode is stopped here.

5

Select the mode: Default - Automatic sequence is executed with the stored transitions MES software is fully controlled by MES software

4.6.4 Operation mode Home Submenu operating mode

Operation mode is active, the setup can be started or an operation mode can be selected.

Operation

Position

Description

1

Application area: here the status of the mounted application is displayed or the parameters are entered. Start: Green when started Ready: Green when ready Busy: Green when the application processes an order Reset: Green when the application is directed Init Pos .: Green when the basic position is reached Application active: green when the application is logged on to the basic module Prog.: Display of active program number Bott.fuse.: not used Top fuse.: not used PCB pos.: Position of circuit board inside the box

2

Area Order Carrier ST1 - the information provided by MES are standing on the workpiece carrier

Carrier ID: Carrier number ONo: Order number OPos: Order position PNo: Part number OpNo: Operation number Resc: Resource RFID Busy ( set hook to activate RFID)

3

Area Order Carrier ST2 - the information provided by MES are standing on the workpiece carrier

Carrier ID: Carrier number ONo: Order number OPos: Order position PNo: Part number OpNo: Operation number Resc: Resource RFID Busy ( set hook to activate RFID)

Submenu overview MES Mode

64 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Submenu overview Default Mode

Operation

Position

Description

1

Application area: here the status of the mounted application is displayed or the parameters are entered. Start: Green when started Ready: Green when ready Busy: Green when the application processes an order Reset: Green when the application is directed Init Pos .: Green when the basic position is reached Application active: green when the application is logged on to the basic module Prog.: Display of active program number Bott.fuse.: not used Top fuse.: not used PCB pos.: Position of circuit board inside the box

2

Area RFID ST1 branch position: here are the informations read out by the RFID tag ST1

In: here is the transition of the incoming condition

Out: here is the transition which is written down to the RFID before leaving the application module

Carrier init: Here you can specify whether the carrier is to be initialized. If this option is activated, every incoming product carrier is processed independently of the RFID condition code with the settings of the "Init" line of the transition table.

Number: Set: determines in this context, how many goods carriers should be initialized according to the above procedure.

Act: Shows how many goods carriers have been initialized.

RFID active (tick to activate RFID)

3

Area RFID ST2 assembly position: here are the informations read out by the RFID tag ST2

In: here is the transition of the incoming condition

Out: here is the transition which is written down to the RFID before leaving the application module

Carrier init: Here you can specify whether the carrier is to be initialized. If this option is activated, every incoming product carrier is processed independently of the RFID condition code with the settings of the "Init" line of the transition table.

Number: Set: determines in this context, how many goods carriers should be initialized according to the above procedure.

Act: Shows how many goods carriers have been initialized.

RFID active (tick to activate RFID)

66 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Submenu user

Here it is possible to create different operators. The function is independent of the selected mode (MES or default)

Click on the button "User Dialog" to open the following window.

If you click on the User or Password fields, the input window opens and the user data can be entered.

Operation

Here the user data can be entered, confirm with the return key.

68 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Position number

description

1

Display robot inputs (green if active) xStop2 - movement stopped xStart - motion started xIOEna - the robot is controlled by an external controller xSlotInit - Slot 1 of the robot is initialized xSrvON - Servo mode switched on xSrvOFF - Servo mode switched off xErrReset - Reset error xRcReady - Drive Unit of the robot is ready xBatErr - the battery of the robot is empty xPrgOut - Program area outputs is selected xOvrdOut - Override range Outputs is selected xErrOut - the robot has an error xATTOMPD - The robot is in automatic mode XTEACHMID - the robot is in manual mode XRobHome - the robot is in the home position xAbovePCB - the robot is above the board XCntZero - reset counter to zero

2

Control robot (blue if active) Connect - connect to the Drive Unit Start Prog. - start the robot program xReady - the robot is ready xBusy - the robot is busy (display current step) xConnected - connection drive unit made

3

Program number - Program number as in the drive unit PCB Pos. - Position of the board inside the box Return value - Return value of the robot program Repeat - try again Exit Cycle - end the current cycle

4

Textual description of the return value

4.6.5 Operating mode Setup Application – Mitsubishi robot

Operation

Position number

description

1

Drive conveyor 1 right / left Left: Conveyor moves counterclockwise to the left Drive 1: Display conveyor belt 1 Right: conveyor moves clockwise to the right

2

To left: move conveyor to the left (actuator QA1_A2 is activated, lights up blue when active) Slow pre selection: set the conveyor speed slowly Slow: move the conveyor slowly (actuator QA1_A3 is activated, lights up blue when active) To right: move conveyor to the right (actuator QA1_A1 is activated, lights up blue when active)

3

Drive conveyor 2 right / left Left: Conveyor moves counterclockwise to the left Drive 2: Display conveyor belt 2 Right: conveyor moves clockwise to the right

4

To left: move conveyor to the left (actuator QA2_A2 is activated, lights up blue when active) Slow pre selection: set the conveyor speed slowly Slow: move the conveyor slowly (actuator QA2_A3 is activated, lights up blue when active) To right: move conveyor to the right (actuator QA2_A1 is activated, lights up blue when active)

5

Drive conveyor 3 right / left Left: Conveyor moves counterclockwise to the left Drive 3: Display conveyor belt 3 Right: conveyor moves clockwise to the right

6

To left: move conveyor to the left (actuator QA3_A2 is activated, lights up blue when active) Slow pre selection: set the conveyor speed slowly Slow: move the conveyor slowly (actuator QA3_A3 is activated, lights up blue when active) To right: move conveyor to the right (actuator QA3_A1 is activated, lights up blue when active)

7

Display conveyors and stoppers (light up green when active)

Setup – belt 1-3

70 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Position number

description

1

Shut down stopper down: Move stopper downwards (actuator G_MB20 is activated, lights up blue when active) G1_BG20: Sensor G1_BG20 stopper down (lit green when active) Stopper: display stopper

2

Area RFID MES Mode: Display of order data Default Mode: Display of the RFID state

3

Describe and read the RFID area initialize: set RFID data to zero read: Read out RFID data write: write current data on RFID Delete data: all data in the input mask is deleted - not directly on the RFID (for easier entry)

4

Area Display of the active sensors (lit green when active) and actuators (lit orange if active) on the stopper

5

Display of the RFID read status

Setup – Stopper 1

Operation

Position number

description

1

Shut down stopper down: Move stopper downwards (actuator G_MB30 is activated, lights up blue when active) G1_BG30: Sensor G1_BG30 stopper down (lit green when active) Stopper: display stopper

2

Area RFID MES Mode: Display of order data Default Mode: Display of the RFID state

3

Describe and read the RFID area initialize: set RFID data to zero read: Read out RFID data write: write current data on RFID Delete data: all data in the input mask is deleted - not directly on the RFID (for easier entry)

4

Area Display of the active sensors (lit green when active) and actuators (lit orange if active) on the stopper

5

Display of the RFID read status

Setup – Stopper 2

72 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Position number

description

1

Shut down stopper down: Move stopper downwards (actuator G_MB42 is activated, lights up blue when active) G1_BG42: Sensor G1_BG42 stopper down (lit green when active) Stopper: display stopper

2

Area Display of the active sensors (lit green when active) and actuators (lit orange if active) on the stopper

Setup – Stopper 3

Operation

Position number

description

1

operate Shunt

Straight: set the shunt to straight (Actuator G_MB40 is activated, lights blue when active)

G1_BG40: Sensor G1_BG40 Shunt straight into position (lights up green when active)

Gate: Display shunt

G1_BG41: Sensor G1_BG41 Turn shunt to Bypass position (lit green when active)

Bypass: turn shunt to bending / bypass (Actuator G_MB41 is activated, lights blue if active)

2

Area Display of the active sensors (lit green when active) and actuators (lit orange if active) on the stopper

Setup – Shunt

74 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Position number

Description

1

Display input milling machine (green when active) Auto – milling machine in automatic mode Alarm – error at milling machine alarm active Busy – milling machine busy Referenced – milling machine has made the reference move DoorOpen – door at milling machine is opened ClampOpen – vice at milling machine is opened ClampClosed – vice at milling machine is closed DncConnected – connection to DNC controller is established DncError – connection to DNC controller is faulty CncPrgError – CNC program is faulty

2

Status display of milling machine (blue when active) xReady – milling machine is ready xConnected – connection to milling machine is established iStep – display of step number from actual sequence StartDnc –connect to DNC controller EndDnc – disconnect DNC controller OpenDoory – open door of milling machine LoadPrg – load program at milling machine StartPrg – execute program milling machine

3

Actual program - display Program No. - display

Mill 55

Operation

4.6.6 Operation mode Parameters Set parameters of the application module on the HMI

To set up the application module, the application module must be set to setup mode.

1. On the Start screen, click Setup

2. Change to parameter page (1) and select application (2).

76 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Position number

Description

1

Robot program number for CNC loading : here the program number for loading the CNC machine is announced

2

CNC program number: here the CNC program is announced

3

Robot program number for CNC loading : here the program number for unloading the CNC machine is announced

4

Enable application: Here, a tick is set to activate the application

5

Stop the belt before the application starts: The conveyor is stopped before the application starts to work - set the hook for this

6

Robot: Switch off Servo after program end: set hook to switch off the Servos of the robot after a program is ended

Operation

Sub menu - Transitions

78 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Position number

description

1

Belt 1 Start / Stop by sensors: Hook set when the belt should be switched automatically with the sensors. Switch on when Sensor at belt beginning signals a carrier, switch off when the sensor at the end of the belt signals the carrier passing by

2

Belt 1 energy saving mode with sensors: If no workpiece is detected on the belt via the sensors, the belt is switched off

3

Stopper 1: Check the jam at the belt outlet: The carrier is only released from the stopper if the belt is not occupied at the belt outlet.

4

Belt 2 Start / Stop by sensors: Hook set when the belt should be switched automatically with the sensors. Switch on when Sensor at belt beginning signals a carrier, switch off when the sensor at the end of the belt signals the carrier passing by

5

Belt 2 energy saving mode with sensors: If no workpiece is detected on the belt via the sensors, the belt is switched off

6

Stopper 2: Check the jam at the belt outlet: The carrier is only released from the stopper if the belt is not occupied at the belt outlet.

7

Belt 3 energy saving mode with sensors: If no workpiece is detected on the belt via the sensors, the belt is switched off

Sub menu application

Operation

Position number

Description

1

Button Calibrate Screen - If buttons react inaccurately, calibration of the touch screen can be restored

2

Button call cleaning screen - the screen can be cleaned here. The touch function is interrupted and unintentional operation is excluded

3

Button Diagnostics - Call up the PROFINET diagnostics

4

Button set time & date: The time and date of the HMI touch panel can be set here.

5

Terminate Runtime: The runtime is terminated and returned to Windows.

6

Button Open system control: Windows system control is opened

7

Button Transfer: Runtime is closed and the transfer mode of the HMI is called

8

Flag displays only current language. By clicking on button next to the flag language can be switched

9

Button language: here the language can be changed

10

Input field for date / time. Click on the "Set time & date" button to accept date / time

11

Display date and time of the PLC

12

Display date and time of the HMI touch panel

13

Display of the MES IP address additionally the IP of the MES can be set here. (Password protected) User: festo, PW: festo)

14

Input fields for your own resource number, query port and status port of the MES connection

4.6.7 Operation mode System - settings

The system can be set in this operation mode

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Operation

4.7 Automatic operation

4.7.1 Start automatic

The operation is the same for all application modules and modules, for the description the basic module is used with an application module Drilling.

The general rule: A blinking button is a prompt to start an action. A button with a glowing background indicates that the action described on the button is currently being executed. A gray button with a blue font indicates that this function is selectable.

1. Switch on the station and wait until HMi is raised. The following screen appears

2. Press Setup button

Operation

3. Select the default or MES mode, for the example the default mode is selected

4. Press the automatic button

5. Automatic is active

82 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

4.7.2 Stop automatic

1. Press the cycle end button, the automatic sequence is immediately stopped.

Operation

4.8 Writing on the RFID tag manually

4.8.1 Pallet carriers

In order to describe a pallet carrier with a specific ID, or to get information on which data is stored on the pallet carrier, it is possible to read this data or to describe the tag. For this, it is necessary that a pallet carrier with a functioning tag is at one of the stopper positions and the station is switched on. The following example is guilty for all read out positions where pallet carriers can be read out.

1. Select the Setup mode

2. Select the stopper from the setup menu on the left

3. If an RFID is detected, this is indicated by "tag present". (TF80 and button "tag present" are green)

4. The data of the RFID tag can be read out and displayed by pressing the "read" button.

5. Press the Delete Data button

For easier input, all data is only deleted in the input mask, the data remains on the tag itself.

84 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

6. Enter the desired data in the field (all fields which are white in background can be edited)

MES Mode Carrier ID - displays or enter the carrier number ONo - the order number is displayed or entered here OPos - the order position is displayed or entered here PNo - the part number is displayed or entered here Resource - here the resource is displayed or entered Operation - the number of the operation is displayed or entered here DefaultMode State code - here the state code for the start condition is entered, if these match the transition tables, the parameters are read out and the automatic sequence of the application is started. Parameter 1 = 1 - Input of the 1 parameter value (e.g., 1 / left side drilling) Parameter 1 = 2 - Enter the 2 parameter value (e.g., 2 / right side drilling) Parameter 1 = 3 - Input of the 3 parameter value (e.g., 3 / both sides drilling) Parameters 2 - 4 - not used in this example

7. Press the "Write" button to write the changes made to the tag.

Operation

4.8.2 Boxes

In order to describe a box with a certain ID, or to get information about what data is on the box, it is possible to read this data or to describe the tag. For this it is necessary that a box with a working tag is located at one of the readout positions and the station is switched on. The following example applies to all readout positions that can read an ID of boxes.

1. Select the Setup mode

2. Select the module with the read out position from the menu on the left

3. If an RFID is detected, this is indicated by "tag present". (TFxx and button "tag present" are green)

4. The data of the RFID tag can be read out and displayed by pressing the "read" button.

5. Press the Delete Data button

For easier input, all data is only deleted in the input mask, the data remains on the tag itself.

6. Entry of the desired data in the field (all fields with a white background can be edited)

MES Mode and default mode are identically ONo – without function OPos – without function BoxID – here the IB number of the box is displayed or entered BoxPNo – Here, the part number of the box and the retainer for the workpieces to be picked up are displayed or entered.

7. Press the „write“ button in order to write the performed modifications on the tag.

86 © Festo Didactic CP Factory ° Robot feeding for mill

Operation

Parameter-Number

Description

1

Program number for loading [-]

1: load CNC with workpiece (robot)

Limitation: No limitation of the value in the transition table

2

CNC Program number [-]

1: process workpiece (CNC)

Limitation: No limitation of the value in the transition table

3

Program number for unloading [-]

2: Remove workpiece from CNC (robot)

Limitation: No limitation of the value in the transition table

4

Not used

Operation

Parameter-

Number

Description

No.

Name

193

Start robot and mill

1

Program number loading [-]

Limitation: No limitation, Value: 1, changeable

2

Program number CNC [-]

Limitation: No limitation, Value: 1, changeable

3

Program number unloading [-]

Limitation: No limitation, Value: 2, changeable

4

Processing time [s]

Limitation: none, value: 5s, changeable

Note: This parameter is only included in the internal time calculation of the work plan and has no effect on the error handling of the station.

4.8.3 Parameter CP Factory feeding robot and mill

Default:

MES:

Components

Performance

Inputs

32 Inputs for communication

Outputs

32 Outputs for communication

Max. reservation

1 work piece/pallet

5 Components

5.1 Mitsubishi Robot RV-4FL

For the transport of the workpieces, a vertical- articulated arm robot is used. This is an industrial robot with 6 axis. The repetition accuracy of the robot positioning is  0.02mm. Its maximum speed amounts to 9900 mm/s. There is an end position and overload monitoring programme integrated. The maximum reach of the robot arm is 648,7 mm.

RV-4FL

88 © Festo Didactic CP Factory ° Robot feeding for mill

Components

Position

Description

1

Emergency stop

2

Down button

3

CHNG button

4

Display

5

Key switch for teach or auto modes

6

Interface cover for USB and battery

7

Plug for teach pendant

8

Servo on button

9

Servo off button

10

Start button

11

Up button

12

Main switch

13

END button

14

RESET button

15

Stop button

5.1.1 Drive Unit CR750-D

The Drive Unit is the controller for the robot.

Components

Position

Description

1

CN1 for robot communication

2

CN2 for robot communication

3

CNUSER 11

4

CNUSER 12

5

CNUSER 13

6

Slot 1 / for connector 1 (in/output 0-15)

7

Slot 2 / for connector 2 (in/output 16-31)

8

CNUSER 2

9

LAN1 for ethernet

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

90 © Festo Didactic CP Factory ° Robot feeding for mill

Components

5.1.2 Teach pendant R32TB

The Teach pendant is required in order to be able to use the robot in the stand alone mode. There are different functions of the buttons depending on the mode of operation selected. You can choose the following two different modes by the key actuator on the Drive Unit.

 Auto position (OP) for the stand alone mode  Auto position (EXT) for the communication with other controls  Teach position for the Teach mode.

Teachpendant

Components

5.1.3 Teachpendant R56TB

To operate the robot in standalone 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 standalone mode.  Position Auto (EXT) for communication with other controller.  Position Teach for teach mode.

Teachpendant

92 © Festo Didactic CP Factory ° Robot feeding for mill

Components

Position

Description

1

CN1 cabel

2

CN 2 cabel

3

Drive Unit CR750-D

4

50 Pin cable from Ria-Box to slot 1 / there is a special cable necessary, this cable is plugged at the Drive Unit and then connected to the 50 PIN cable

5

RIA Box

5.1.4 Set up

Robot RV4-FL set up example for standalone mode

Components

Position

Description

1

TB 2 Cable to Drive Unit

3

Programming PC

4

Drive Unit CR750D

5

Cable to Ethernet interface

Robot RV4-FL set up example for standalone mode

94 © Festo Didactic CP Factory ° Robot feeding for mill

Components

Position

Description

1

TB 2 Cable to Drive Unit

3

Programming PC

4

Drive Unit CR750D

5

Cable to Ethernet interface

Robot RV4-FL set up example for standalone mode

Components

Sensor Name

RV-4FL Robot

SIEMENS PLC

Variable Name

Input/ Output

Robot address

Data Type

Comment

PLC Address

connected to robot IO card

CNC

DoorOpened

Input

16

Bit

Milling machine door opened

CNC

DoorClosed

Input

17

Bit

Milling machine door closed

CNC

ViceOpened

Input

18

Bit

Milling machine vice opened

CNC

ViceClosed

Input

19

Bit

Milling machine vice closed

CNC

CNCRefPose

Input

20

Bit

Milling machine in reference position

CNC

CNCStopped

Input

21

Bit

Milling machine program is stopped

CNC

CNCInError

Input

22

Bit

Milling machine error in status

Robot status Info region

#STOP2

Input

2000

Bit

Stop

100.0

#START

Input

2001

Bit

Program started

100.1

#IOENA

Input

2002

Bit

Set operation rights enable

100.2

#SLOTINIT

Input

2003

Bit

Reset program

100.3

#SRVON

Input

2004

Bit

Servo power supply on

100.4

#SRVOFF

Input

2005

Bit

Servo power supply off

100.5

#ERRRESET

Input

2006

Bit

Reset error input signal

100.6

#PRGSEL

Input

2007

Bit

Choose program input signal

100.7

#OVRDSEL

Input

2008

Bit

Choose override input signal

101.0

#PRGOUT

Input

2009

Bit

Program number output request

101.1

#OVRDOUT

Input

2010

Bit

Override value request

101.2

#ERROUT

Input

2011

Bit

Error number output request

101.3

#Reserved

Input

2012 2015

Reserved

#IODATA

Input

2016 2031

Word

Numeric value input

102 - 103

DI_RetryLastSt ep

Input

2032 Bit

Retry last step

104,0

DI_ExitCurrCyc le

Input

2033 Bit

Exit current program cycle

104,1

Reserve_RobS tate1

Input

2034 2039

Reserved for extension

Reserve_RobS tate2

Input

2040 2047

Byte

Reserved for extension

105

5.1.5 Interface Drive Unit

Components

Sensor Name

RV-4FL Robot

SIEMENS PLC

Robot Variable Info Region

ReservedWord1

Input

2048 - 2063

Word

Reserved Word 1

106 - 107

ReserveByte1

Input

2064 - 2071

Byte

Reserved Byte 1

108

ReserveByte2

Input

2072 - 2079

Byte

Reserved Byte 2

109

ReserveByte3

Input

2080 - 2087

Byte

Reserved Byte 3

110

ReserveByte4

Input

2088 - 2095

Byte

Reserved Byte 4

111

ReserveByte5

Input

2096 - 2103

Byte

Reserved Byte 5

112

ReserveByte6

Input

2104 - 2111

Byte

Reserved Byte 6

113

ReserveByte7

Input

2112 - 2119

Byte

Reserved Byte 7

114

ReserveByte8

Input

2120 - 2127

Byte

Reserved Byte 8

115

ReserveByte9

Input

2128 - 2135

Byte

Reserved Byte 9

116

ReserveByte10

Input

2136 - 2143

Byte

Reserved Byte 10

117

Connected

PLC card

BG50

DI_WPPalAvail

Input

2144

Bit

Workpiece pallet is available

118,0

BG51

DI_WPAtStopAvail

Input

2145

Bit

Workpiece at stopper position

118,1

ReserveSensor1

Input

2146 - 2151

Bit

Reserved for sensor group 1

ReserveSensor2

Input

2152 - 2159

Byte

Reserved for sensor group 2

119

ReserveSensor3

Input

2160 - 2167

Byte

Reserved for sensor group 3

110

ReserveSensor4

Input

2168 - 2175

Byte

Reserved for sensor group 4

111

Connected with robot I/O card

CNC

StartNCPrg

Output

24

Bit

Start loaded CNC program

CNC

StopCNC

Output

25

Bit

Stop CNC program

CNC

OpenDoor

Output

26

Bit

Open door of CNC machine

CNC

CloseDoor

Output

27

Bit

Close door of CNC machine

CNC

OpenVice

Output

28

Bit

Open vice of CNC machine

CNC

CloseVice

Output

29

Bit

Close vice of CNC machine

Components

Sensor Name

RV-4FL Robot

SIEMENS PLC

Robot Status Info Region

#STOP2

Output

2000

Bit

Stop

100.0

#START

Output

2001

Bit

Start program

100.1

#IOENA

Output

2002

Bit

Set operation rights enable

100.2

#SLOTINIT

Output

2003

Bit

Enable choose program

100.3

#SRVON

Output

2004

Bit

Servo on

100.4

#SRVOFF

Output

2005

Bit

Servo off

100.5

#ERRRESET

Output

2006

Bit

Output signal for errors

100.6

#RCREADY

Output

2007

Bit

Controller ready

100.7

#BATERR

Output

2008

Bit

Power supply is missing

101.0

#PRGOUT

Output

2009

Bit

Program number output signal

101.1

#OVRDOUT

Output

2010

Bit

Override value output signal

101.2

#ERROUT

Output

2011

Bit

Error number output signal

101.3

#ATTOPMD

Output

2013

Bit

Teachmode output

101,5

#TEACHMD

Output

2014

Bit

Teachmode output

101,6

#IODATA

Output

2016 2031

Word

Numeric value output

102 - 103

IsRbtArmHome

Output

2032

Bit

Robot arm in basic position

104,0

IsRbtArmInByP ass

Output

2033 Bit

Robot arm over bypass

104,1

IsRbtArmInMill

Output

2034

Bit

Robot arm inside milling machine

104,2

Reserve_RobS tate1

Output

2035 2039

Reserved for robot status

Reserve_RobS tate2

Output

2040 2047

Byte

Reserved for extension

105

Robot Variable Info Region

ReservedWord 1

Output

2048 2063

Word

Reserved Word 1

106 - 107

ReturnValue

Output

2064 2071

Byte

Return value robot

108

ReserveByte1

Output

2072 2079

Byte

Reserved Byte 1

109

ReserveByte2

Output

2080 2087

Byte

Reserved Byte 2

110

ReserveByte3

Output

2088 2095

Byte

Reserved Byte 3

111

ReserveByte4

Output

2096 2103

Byte

Reserved Byte 4

112

ReserveByte5

Output

2104 2111

Byte

Reserved Byte 5

113

Components

Sensor Name

RV-4FL Robot

SIEMENS PLC

ReserveByte6

Output

2112 2119

Byte

Reserved Byte 6

114

ReserveByte7

Output

2120 2127

Byte

Reserved Byte 7

115

ReserveByte8

Output

2128 2135

Byte

Reserved Byte 8

116

ReserveByte9

Output

2136 2143

Byte

Reserved Byte 9

117

CNC

DO_CNCAutoM ode

Output

2144 Bit

CNC machine in automatic mode 118,0

CNC

DO_CNCPrgRu ning

Output

2145 Bit

Program in CNC machine is running

118,1

CNC

DO_CNCDoorO pen

Output

2146 Bit

CNC door opened 118,2

CNC

DO_CNCViceO pen

Output

2147 Bit

CNC vice opened 118,3

ReserveSensor 1

Output

2148 2151

Reserved for sensor group 1

ReserveSensor 2

Output

2104 2011

Byte

Reserved for sensor group 2

119

ReserveSensor 3

Output

2160 2167

Byte

Reserved for sensor group 3

110

ReserveSensor 4

Output

2168 2175

Byte

Reserved for sensor group 4

111

Components

5.1.6 Parameter

For the configuration of a new Drive Unit, you have to adjust the following parameters. After the configuration, the Drive Unit has to be switched off and then switched on again. Tool offsets:

 MEXTL1= 0,0,205,0,0,0  MEXTL2= 0,0,170,0,0,0  MEXTL3= 0,0,151.50,0,0,0  MEXTL4= 0,0,0,0,0,0

Communication parameter DP

 PBNUM=10;  STOP2=2000,2000;  START=2001,2001;  IOENA=2002,2002;  SLOTINIT=2003,2003;  SRVON=2004,2004;  SRVOFF=2005,2005;  ERRRESET=2006,2006;  PRGSEL=2007;  RCREADY=-1,2007;  OVRDSEL=2008;  BATERR=-1,2008;  PRGOUT=2009,2009;  OVRDOUT=2010,2010;  ERROUT=2011,2011;  ATTOPMD=-1,2013;  TEACHMD=-1,2014;  IODATA=2016,2031,2016,2031;

Communication parameter Ethernet Camera:

 COMDEV=Us,"","OPT12","OPT13","","","","","";  NETHSTIP=Us,"192.168.0.2","192.168.0.3","Camera_IP_Address","192.168.0.5","192.168.0.6","192

.168.0.7","192.168.0.8","192.168.0.9","192.168.0.10";

 NETPORT=10000, 10001, 10002, Camera_Port, 10004, 10005, 10006, 10007, 10008, 10009  NETMODE=Ud,1,1,0,1,1,1,1,1,1;

Slot Parameter:

 SLT1=Us,"3","CYC","START","1";  SLT2=Us,"MONITORHOME","REP","ALWAYS","1";  SLT3=Us,"ENRGSAVEVACU","REP","ALWAYS","1";  SLT4=Us,"PCBTRAYCNTRL","REP","ALWAYS","1";  SLT5=Us,"MONITORPALWS","REP","ALWAYS","1";