SMC Networks FAS-200 User Manual

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FAS-200

USER MANUAL

Equipment for training in flexible integrated
assembling systems

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Technical Description

TEN REASONS FOR CHOOSING THE FAS200 SYSTEM

1. The FAS200 is manufactured entirely from industrial grade materials of maximum
strength and quality.

2. It complies with European safety directives in respect of both low voltage and
machine safety.

3. It may include pallet transfer integrate several modules allowing.

4. The process stations or layouts can work independently or integrated in the system in
cell mode.

5. The PLCs 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 turning mechanism with a total
of 24 variants.

8. The pallets and transfer incorporate a binary coding system using inductive
detectors, which allow the Control System to identify the position of each pallet at any
time.

9. The system allow the development of skills such as: ANALYSIS, INSTALLATION/
ASSEMBLY/ IMPLEMENTATION, MAINTENANCE/ DIAGNOSIS/ FAULT REPAIR,
START-UP/ SET-UP, DESIGN/LAYOUT, PROGRAMMING, PREPARATION OF
DOCUMENTATION, DEFINITION OF PROCEDURES, MEASURING, ETC., integrating
different technologies including: Pneumatics/Electro-pneumatics, Hydraulics/Electro­hydraulics, 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 industrial and educational sectors.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 4 -

INDEX

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

1. CONFIGURATION .......................................................................................................................... 5

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

FAS-230 LINEAR TRANSFER MODULE: TRANSPORT SYSTEM ........................................................ 13

TROUB-200 FAULT SIMULATION SYSTEM ................................................................................... 17

FAS-201 BASE FEEDING/VERIFICATION MODULE............................................................................ 18

FAS-202 BASE REJECTING/TRANSFERING MODULE............................................................................... 23

FAS-203 BEARING FEEDING/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/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 REJECTING MODULE ....................................................... 84

FAS-216 WAREHOUSE 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

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 5 -

1. CONFIGURATION

The FAS-200 system is the ideal answer to integral training in industrial
automation. It is fully modular and flexible equipment 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.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 6 -

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-205 Hydraulic Pressing module 1
FAS-206 Hydraulic Press Transfering module 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 module 1
FAS-220 Pallet transfer module 2
FAS-230 Linear transfer for 4 modules 4
FAS-200 Empty module for future projects x

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 7 -

FAS200 CONFIGURATION:

The modules that make up the configuration of this system FAS200 are:

Figure 2: Example of system FAS200 with configuration 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

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 8 -

System 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.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 9 -

2. GENERAL OVERVIEW:

The flexible assembly system has been specially conceived for persons to
acquire professional capabilities in connection with the Occupational Groupings
of Electricity/ Electronics and Maintenance, such as:

- Installation, Electromechanical Maintenance and Line Transport.

- Industrial Equipment Maintenance.

- Automatic Control and Regulation Systems.

Figure 4: System FAS200 with different configurations.

It enables the development of various skills associated with pneumatic, electro­pneumatic, 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 sensor types:

- Magnetic detectors.

- Inductive detectors.

- Optical fiber sensors.

- Photoelectric detectors.

- Capacitive detectors.

- Pressure and vacuum switches.

- Linear encoders….

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 10 -

The system comprises a flexible automation cell which carries out an assembly
process involving a number of predetermined 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.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 11 -

The process modules function either independently of the transport system, in
in single or couple modes, or integrated into it, in cell mode. The modules are
located in a side of the linear transfer, and may be withdrawn for re-positioning
in a different order (the repositioning of different modules of the system can
mean repositioning of stoppers, lifters-positioners and reprogramming of the
controllers of the system), moved for future extensions or work 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 desired. In addition, students may
design and build their own controls with different PLCs and
subsequently integrate them in the station, thereby developing
a further series of skills envisaged in the Training Cycles for
those persons who form the target group for the Cell.

Figure 11: Electrical
panel of a module.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 12 -

The front of each station incorporates the start, stop, step-by­step/continuous cycle and reset pushbuttons. In addition, the control
pushbuttons incorporate a main switch on/off and emergency pushbuttons for
emergency stops.

Figure 12: Control pushbuttons of a module.

The system is modular and may be extended, allowing future incorporation of
other process modules according to user needs.

The modules are mounted on aluminum sections, forming tables with a large
surface area and multiple 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 and material.
Process E: Pick and Place cover and verification of its orientation, material and
color.
Process F: Fit screws.
Process G: Robot screw driving.
Process H: Quality control by artificial vision.
Process I: Unloading, storage and palletization of final assembly

In addition to transport processes between modules or between linear
conveyors.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 13 -

FAS-230 LINEAR TRANSFER MODULE: TRANSPORT SYSTEM

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.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 14 -

Different layouts can be defined for future expansions. The transfer follows a
rectangular path or linear path. The master PLC controls and coordinates the
rest of the PLCs connected to the network and it is located in the “body feeding
and checking” station (FAS201 module).

There is a longitudinal channel in one side of each module and of the linear
transfer to provide the electrical power connections and the air supply
connections between
the different stations
(and in some
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 16: Binary code on
the pallets.

In front of some modules (which need to interact with the linear transfer
system), there is a mechanical end to stop the pallets, and, depending on the
particular process, a further series of elements for lifting, centering, turning, etc.
All these transport system actuators, stoppers, lifters, positioners and

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 15 -

pallet transfers are operated by a system of solenoid valves connected to each
module.

Figure 17: Stopper and lifter with microswitch and inductive detectors.

Both the pallet retention point and the relative position of the module within the
system FAS200 may be varied, making it simple to modify the distribution of the
component bases of the FAS-200. Although not recommended such
modifications 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 4/6 modules)):

1 Motor 24 VDC HIWIN (AM1 M12029A1).
1 Power supply 24 VDC / 60 W OMRON (S8VK-G06024).

Composition:

Actuators (each 2 modules):

- 1 Compact double-acting cylinder Ø32, Stroke: 25mm (CQ2B32-25D­XSE040). Controlled by 5/2 way monostable solenoid valve.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 16 -

Actuators (some modules):

- 1 Compact double-acting cylinders with guide Ø16, Stroke: 30mm (MGPM16­30Z), 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).

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 17 -

TROUB-200 FAULT SIMULATION SYSTEM

Most of the modules incorporate a Fault Simulation System TROUB-200 fitted
to the side of each module or in the electrical panel, depending 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 component can be found.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 18 -

FAS-201 BASE FEEDING/VERIFICATION MODULE

Figure 20: FAS201 Base Feeding/Verification Module.

FUNCTION OF THE MODULE:

This first module feeds the body or
base which is the 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 position is provided by a

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 19 -

microswitch which sends the appropriate signal to the PLC of the second
module which in turn sends the signal “start cycle” to the PLC of this first
module.

The confirmation of the body is in correct orientation is got by a pneumatic
cylinder like a checker turning on an internal flag of the PLC, signal used by this
PLC to send the signal “body OK” to the PLC of the next module.

INTEGRAL PARTS:

The first 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.

• 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 of
its own weight and that of the ones
above it.

Figure 22: Body feeder.

The body is extracted by a pneumatic cylinder which
pushes against a pusher shaped to match the profile of the
body. An inductive sensor is used to alert about lack of
bodies in the feeder.

Figure 23: Inductive sensor.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 20 -

• Verification of position:
The body contains a housing in which the other
components are fitted. This housing must always be
facing upwards when the base is placed on the pallet
(in the next module). To check correct body
orientation, a check is made by a cylinder which
advances and inserts a cylindrical part in the body
housing. If the body is inverted, this part cannot enter
the housing, the cylinder 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 module.

The cylinder is rectangular, to prevent the
pusher from turning.

Figure 25: Cylinder with a pusher.

TECHNICAL DATA:
Dimensions:

Table of slotted aluminium, 450 x 582 mm. Height 900 mm.

Air treatment unit:

Filter to 5 µm, pressure regulator and pressure gauge.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 21 -

Control panel:

Start, stop, reset pushbuttons. Emergency stop button, main switch on/off,
mode selector (auto-man), no material indicator and error pilot indicator.

Composition of module manipulators:

Body feeder
Magazine capacity: 12 bodies.

Actuators:

- Double-acting pusher cylinder Ø16, Stroke: 100mm (CD85N16-100-B),
with flow regulators and initial-end position 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:

- Rectangular section pusher cylinder Ø25, Stroke: 200mm (MDUB25­200DMZ), with flow regulators and end position detector. Controlled by 5/2 way
monostable solenoid valve.

Sensors:

- Reed type magnetic detector (D-A93L).

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 22 -

Electrical 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.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 23 -

FAS-202 BASE REJECTING/TRANSFERING MODULE

Figure 26: FAS202 Base Rejecting/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.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 24 -

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 first module sends the signal “end cycle” to the PLC of this second module.

INTEGRAL PARTS:

The second 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.

• 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 on the conveyor belt. The
horizontal axis is carried out by a dual rod cylinder/Double
rod and the vertical axis by a dual rod cylinder.

The terminal element is a vacuum system with a platform
with four suction cups (to absorb possible lack of alignment
in height).

Figure 29: Cartesian manipulator.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 25 -

Suction is generated by a vacuum ejector fitted with a
vacuum switch which sends a signal to the PLC
indicating that the part has been correctly clamped.

Figure 30: Vacuum system.

TECHNICAL DATA:
Dimensions:

Table of slotted aluminium, 450 x 582 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:

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: Parallel and dual rod cylinder Ø20, Stroke: 150mm
(CXSWM20-150-XB11), with flow regulators and initial-end position detectors.
Controlled by 5/2 way bistable solenoid valve.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 26 -

- Vertical axis: Parallel rod cylinder Ø15, Stroke: 50mm (CXSM15-50), with flow
regulators and initial-end position detectors. Controlled by 5/2 way monostable
solenoid valve.

- Vacuum system: 4 telescopic suction 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 inputs/outputs.

• Communication module for PLC network connection.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 27 -

FAS-203 BEARING FEEDING/TRANSFERING MODULE

Figure 31: FAS203 Bearing
Feeding/Transfering Module.

FUNCTION 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.

FLEXIBLE ASSEMBLY SYSTEM FAS200

User Manual for FAS200 - 28 -

This operation begins when the pallet is positioned opposite the fourth module,
held in a determined location by a stopper and a positioner-lifter on the linear
transfer. Confirmation that the pallet is in the correct position is provided by a
microswitch which sends the appropriate signal to the PLC of the fourth module
which in turn sends the signal “start cycle” to the PLC of this third module.

INTEGRAL PARTS:

The third 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.

• 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 effect of its own weight and that of the
ones above it.

F

Figure 33: Bearing feeder.

In this case, there is a bearing presence sensor in the form of a microswitch

which allows the PLC to verify that a bearing really
has been extracted following the feeding
procedure. This makes it possible to determine
when the bearings loaded in the feeder have run
out.

Figure 34: Microswitch.