iCIM Manual Robot assembly station 2 © Festo Didactic GmbH & Co.KG. • iCIM Order-NR.: Type: Manual iCIM Designation iCIM_Robot_Assembly_Vision_A006 Printed: 17.05.2004 Autor: Schober Graphics: Schober Layout: Schober © Festo Didactic GmbH & Co.KG., D-73770 Denkendorf, 2004 Internet: www.festo.com/didactic e-mail: did@festo.com This manual, all text and illustrations contained included, is protected by copyright. Any utilisation outside the limits of the copyright law and other than training purposes are not permissible without our definite approval. This applies in particular to reproductions, operations, translations, micro filming and the storing and processing into electronic systems. Parts of this manual may be copied by the authorised user, exclusively for teaching purposes. Distribution of this documentation, as well as reproduction, use and spread of its contents is prohibited, insofar not permitted explicitly. Offences are liable to compensation. All rights reserved, especially the right to execute registrations concerning patents, designs for use and patterns. © Festo Didactic GmbH & Co.KG. • iCIM 3 The User Manual must be to hand at all times. Keep it close to the machine. This installation was developed and manufactured only for use in basic and further training in the fields of automation and communications. The training company and/or the training staff must ensure that the trainees observe the safety precautions described in the accompanying manuals. Furthermore this manual describes setup and possible uses of the singular stations. It contains all information and data required for commissioning, maintenance and operation. Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any third parties occurring when the installation is used for any purpose apart from training, except Festo Didactic has caused such injury or harm intentionally or by grossly negligence. The manual is divided into four parts: • Part A In addition to technical data, Part A contains an overview of the possible uses of the stations. • Part B Part B contains some exercises and the solutions for this exercises (Not available for each station). • Part C Part C contains the pneumatic and electrical diagrams for the station and the listing of the control programs (Not available for each station). • Part D Part D contains data sheets and technical information about the electrical and electronic modules used. 1 Intended use 4 © Festo Didactic GmbH & Co.KG. • iCIM The list below provides an overview of the most important standards and regulations relating to mechanical, electrical and safety-engineering design and production. • DIN EN 292 -Machine safety • DIN EN 60204 - Electrical equipment of industrial machines • DIN VDE 0113 - See DIN EN 60204 • DIN 40719 - Circuit documentation • VDI 2853 - Technical safety requirements concerning the building, equipping and operation of industrial robots • VDI 2853 - Technical safety requirements concerning automated production systems • VDI 2411 - Terms and explanations in conveying and handling • VDI 2860 - Assembly and robotics - terms • VDI 2861 - Assembly and robotics - characteristic quantities • DIN 19245 - PROFIBUS Part 1-3 As far as possible, the System is maintenance-free. All bearings are lubricated for life. The installation was designed in such a way as to keep the number of wearing parts to a minimum. This does not include machines that are part of optional expansions (such as industrial robots). At this point we would like to point out that this manual and the concept of the operating instructions for a Flexible Training System of this type are regularly updated. To ensure that the instructions are ever more user-friendly, you would help us a great deal by passing on your suggestions for improvement. Please let us know of your suggestions, corrections or ideas, either in writing or via telephone: +49(711-3467-0) List of applicable standards and regulations © Festo Didactic GmbH & Co.KG. • iCIM 5 1 Intended use _____________________________________________________ 3 2 Contents_________________________________________________________ 5 3 Introduction_____________________________________________________ 11 3.1 General_____________________________________________________ 11 3.2 Robot assembly station _______________________________________ 12 3.3 Didactic structure ____________________________________________ 13 3.4 Scope of tasks of the stations __________________________________ 14 3.4.1 Mechanics ______________________________________________ 14 3.4.2 Pneumatics _____________________________________________ 14 3.4.3 Electrics ________________________________________________ 14 3.4.4 Informatics______________________________________________ 14 3.4.5 Bus technology __________________________________________ 14 4 General safety instructions_________________________________________ 15 4.1 Use according to regulations ___________________________________ 15 4.2 Handling the system __________________________________________ 15 4.2.1 Dangers in handling the machine____________________________ 15 4.2.2 Safety precautions in standard operation _____________________ 15 4.2.3 Dangers due to electric current _____________________________ 16 4.2.4 Dangers due to pneumatic energy ___________________________ 16 4.2.5 Maintenance – Servicing – Malfunction removal ________________ 17 4.2.6 Organisational measures __________________________________ 17 4.3 Personnel___________________________________________________ 17 2 Contents Contents 6 © Festo Didactic GmbH & Co.KG. • iCIM 4.3.1 Notes on personnel _______________________________________ 17 4.3.2 Training operations _______________________________________ 17 4.3.3 Outside training operations ________________________________ 17 4.3.4 Safety symbols __________________________________________ 18 5 Commissioning __________________________________________________ 19 5.1 Transport ___________________________________________________ 19 5.2 Set up______________________________________________________ 20 5.2.1 General information ______________________________________ 20 5.2.2 Robot assembly station ___________________________________ 20 5.3 Commissioning ______________________________________________ 24 5.3.1 Pneumatic commissioning _________________________________ 24 5.3.2 Electric commissioning ____________________________________ 24 5.3.3 Connecting communication cables___________________________ 25 5.3.4 Establishing communication connections _____________________ 26 5.4 Start up the system ___________________________________________ 27 5.4.1 Start up conditions _______________________________________ 27 5.4.2 general information_______________________________________ 27 5.4.3 Adjust AS/RS station______________________________________ 28 5.4.4 Pallet handling/quality station______________________________ 28 5.4.5 Robot assembly station ___________________________________ 28 5.4.6 Assembly station _________________________________________ 29 5.4.7 Adjust transport system ___________________________________ 29 Contents © Festo Didactic GmbH & Co.KG. • iCIM 7 5.4.8 Start up cell control (COSIMIR CONTROL) _____________________ 30 5.4.9 Start-up of processes _____________________________________ 30 5.5 Shut down the system_________________________________________ 30 6 Operation_______________________________________________________ 31 6.1 General operation notes _______________________________________ 31 6.1.1 Behaviour rules __________________________________________ 31 6.1.2 Operation rules __________________________________________ 31 6.2 Process description___________________________________________ 32 6.2.1 Robot assembly station ___________________________________ 32 6.2.2 General process description ________________________________ 33 6.2.3 Process 530 _____________________________________________ 33 6.3 Order codes Robot assembly station Drive Unit – COSIMIR CONTROL __ 34 6.4 Operation panel______________________________________________ 38 6.5 Adjustment _________________________________________________ 39 6.5.1 Requirements ___________________________________________ 39 6.5.2 Reset mode _____________________________________________ 40 6.6 Automatic __________________________________________________ 40 6.6.1 start automatic __________________________________________ 40 6.6.2 Automatic mode _________________________________________ 40 6.6.3 Stop automatic __________________________________________ 40 6.7 Mitsubishi robot RV-2A _______________________________________ 41 6.8 Drive Unit CR-1 for RV-2A ______________________________________ 42 Contents 8 © Festo Didactic GmbH & Co.KG. • iCIM 6.8.1 Functions _______________________________________________ 42 6.8.2 Teach pendant RV-2A _____________________________________ 44 6.8.3 Set up RV-2A ____________________________________________ 45 6.8.4 To operate the robot ______________________________________ 46 6.8.5 Choose program _________________________________________ 49 6.8.6 Change program _________________________________________ 49 6.9 To operate the robot __________________________________________ 50 6.9.1 Teach position example ___________________________________ 51 6.9.2 Interface Drive unit Inputs _________________________________ 52 6.9.3 Interface Drive unit Outputs ________________________________ 53 6.9.4 Program documentation for CR1 and CR2 with ETHERNET ________ 54 6.9.5 Robot programs__________________________________________ 58 7 Technology _____________________________________________________ 59 7.1 drawings ___________________________________________________ 59 7.2 Technical datas ______________________________________________ 60 7.3 Modules in use ______________________________________________ 61 7.3.1 Pallet reception __________________________________________ 61 7.3.2 Pen magazine ___________________________________________ 62 7.3.3 Instrument magazine _____________________________________ 63 7.4 Assembly module ____________________________________________ 64 7.4.1 Mitsubishi robot RV-2A ____________________________________ 65 7.5 Workpiece positions __________________________________________ 66 Contents © Festo Didactic GmbH & Co.KG. • iCIM 9 8 Pneumatic ______________________________________________________ 69 8.1 The valve terminal____________________________________________ 69 8.2 Pneumatic supply ____________________________________________ 70 9 Electrical system _________________________________________________ 71 9.1 Power supply ________________________________________________ 71 9.2 Controller___________________________________________________ 71 9.3 Wiring______________________________________________________ 72 9.3.1 I/O-Components _________________________________________ 72 Contents 10 © Festo Didactic GmbH & Co.KG. • iCIM [...]... start with the first steps, e.g the robot • First the mechanical assembly is considered The robot s radius of action requires integration into the location of the robot • The following step could be the connection of all cables required for operation and the set-up of the robot • Moving the robot and teaching the required positions are the first real operations with the robot, which introduces the user... station The drive unit of the robot supplies the control The robot assembly vision station can be operated individually, in “stand alone” mode, for training purposes with robots • Communication from drive unit to Cosimir Control PC ensues by means of ethernet If the station is operated without the iCIM System, in “stand alone” mode, it is possible to make training on the robot 12 © Festo Didactic GmbH... 5.2.2 Robot assembly station The robot assembly station is set up in its final position, at operating position 2 The installation is adjusted, by means of a spirit level, to a plate height of 785mm, by means of the adjustable feet In case of very uneven ground, it may be necessary to underlay the adjustable feet The station is connected to the transport system, by means of the assembly profile The robot. .. Activate Main switch of xyz assembly station Activate distribution strip of robot assembly station Do not activate the drive unit of the stations robot Unlock the emergency-off switch of all of the stations and confirm with the CONTROLLER ON button • Switch on the PC - COSIMIR CONTROL • The switches of all teach-boxes of the robots are to be set to Disable © Festo Didactic GmbH & Co.KG • iCIM 27 Commissioning... units uncheckedly has to be stopped • No workpiece carriers may be taken by the system © Festo Didactic GmbH & Co.KG • iCIM 31 Operation 6.2 Process description 6.2.1 Robot assembly station Process description inside robot assembly station The robot assembly station is responsible for the assembly of an desk set in different variants Type 1 => base plate with two instruments and pen holder made from brass... types of desksets This process serves as an example for an complete process 6.2.3 Process 530 To produce a deskset the process plan is to split into 2 parallel process parts (P1 and P2) part P1: Retrieve a processed penholder (type depends on selection) from stock and transport pallet to robot assembly station Then move the pallet from the transport carrier inside robot assembly station part P2: •... appear in clear presentation Festo Didactic succeeded in using the most updated industrial hard- and software for this model production © Festo Didactic GmbH & Co.KG • iCIM 11 Introduction 3.2 Robot assembly station The robot assembly station is responsible for the assembly of an desk set in different variants Once a desk set is to be assembled, the required palettes, containing the necessary components,... planning the complete installation design is shown in the following The robot assembly vision station is to line up that a fault-free workpiece handing over can take place Installation design iCIM system © Festo Didactic GmbH & Co.KG • iCIM 21 Commissioning Dimension drawing iCIM 22 © Festo Didactic GmbH & Co.KG • iCIM Commissioning Position robot assembly station © Festo Didactic GmbH & Co.KG • iCIM 23 Commissioning... supply unit, contained in the control cabinet or somewhere in the station 24 © Festo Didactic GmbH & Co.KG • iCIM Commissioning 5.3.3 Connecting communication cables Communication cables robot assembly station If the robot assembly station is to be connected to another installation, for example as described in complete process, communication takes place via ethernet The ethernet cable from the Drive... of the robot • Moving the robot and teaching the required positions are the first real operations with the robot, which introduces the user how to deal with the teach-box • The robot s programming can be started, as soon as the robot can be moved by the teach-box Small programs, which can be created by using the Cosimir/Cosirob software, are expandable for the complex programs • Orders to further stations . __________________________________________ 40 6.7 Mitsubishi robot RV- 2A _______________________________________ 41 6.8 Drive Unit CR-1 for RV- 2A ______________________________________ 42 Contents. _______________________________________________ 42 6.8.2 Teach pendant RV- 2A _____________________________________ 44 6.8.3 Set up RV- 2A ____________________________________________ 45 6.8.4 To operate the robot ______________________________________. _____________________________________ 63 7.4 Assembly module ____________________________________________ 64 7.4.1 Mitsubishi robot RV- 2A ____________________________________ 65 7.5 Workpiece positions __________________________________________