fms50 robot assembly gb a001

Robot Cell

Assembly FMS 50

with

Mitsubishi RV – 2AJ

programmed with

COSIMIR Industrial

Description of the

cell

Table of Contents

2 © Festo Didactic GmbH & Co.

Robot cell - RV – 2AJ

1. Introduction...........................................................................................................................3 2. Wiring of the System ...........................................................................................................4 2.1 Connection of the drive unit with RIA-box ...................................................................5 2.2 Connection RIA – Box XMA, XMB, XMC, XMD..............................................................6 3. Commissioning .....................................................................................................................7

Drive Unit ...............................................................................................................................7 Reset conditions...................................................................................................................7 Process Start .........................................................................................................................7 Changing Program ...............................................................................................................8

4. Robot positions ....................................................................................................................9 4.1 Program FMS_50...........................................................................................................9

5. Robot Inputs and Outputs............................................................................................... 16 Inputs................................................................................................................................... 16 Outputs................................................................................................................................ 16 5.2 Handshake ................................................................................................................... 17

6. FMS50 Robot-Program............................................................................................ 18 6.1 Program structure ...................................................................................................... 18

Version 09.08.2002 HEL


The function of the Robot Cell is assembling different cylinders (metal, black and

red). The raw material is provided by the conveyor system without type coding (check material). Within the cell, the differentiation of the material has to be done

first by using corresponding sensors. Controlling the sensors and actuators of the

assembly process is done directly via the robot drive unit (refer to the RIA-box). That's why this station can be used independently from other stations or a more

complex process.

The communication between the robot cell and the conveyor system is realized with digital I/O-communication.

The following chapte rs comprising the Hardware configuration, this means the cabling of the Robot, the Software configuration of the user program and the

commissioning of the Robot. To program the Robot, COSIMIR Industrial has been

used.

x

1. Introduction


1. The drive unit must be connected with the robot with two cables – CN1 and CN2

on the backside of the unit. 2. The Teach-Panel must be connected to the front side of the drive unit

connection TP.

3. Connect the power-supply to the drive unit. 4. The I/O-interface of the drive unit has to be connected via a 50-pin cable with

Centronics connector to the RIA-box (XMR).

5. The RIA-box has to be connected with the interface of the assembly (XMA), the robot I/Os (XMB), the conveyor system (XMD) and the control panel (XMC), by

using a standardized Sys-Link cable

6. For supervision and programming, please connect the drive unit to the serial COM port of your computer, using the special RS-232-cable.

7. In addition, an external Emergency Stop switch could be connected to the drive

unit backside (green connector, details refer controller manual). If you don't use the external Emergency switch, you have to jumper this input (refer to the

controller manual).

2. Wiring of the System

Robot Arm

CN1/CN2

Drive-Unit

Teach-

Panel

XMR

RIA-Box

SYSLINK XMD

ASi Slave

Conveyor

PC

DC 24V

AC 230V

SYSLINK

XMB

Rob. I/O

SYSLINK

XMA

Assem. I/O XMA

XMC

Control Panel


2.1 Connection of the drive

unit with RIA-box RIA - Box (XMR)

Pin - No. Description/Function Cable Pin - No. connecte with12 0V for Pin 4 - 7 <=> 26 Power supply 0 V3 12 / 24 V for Pin 4 - 7 <=> 1 Power supply 24 VDC4 Output 0 <=> 3 OUT 0 (X2)5 Output 1 <=> 28 OUT 1 (X2)6 Output 2 <=> 4 OUT 2 (X2)7 Output 3 <=> 29 OUT 3 (X2)8910 Output 8 <=> 8 OUT 8 (X2)11 Output 9 <=> 33 OUT 9 (X2)12 Output 10 <=> 9 OUT 10 (X2)13 Output 11 <=> 34 OUT 11 (X2)14 COM0 for Pin 15 - 22 <=> 27 Power supply 0V15 Input 0 <=> 48 IN 0 (X4)16 Input 1 <=> 23 IN 1 (X4)17 Input 2 <=> 47 IN 2 (X4)18 Input 3 <=> 22 IN 3 (X4)19 Input 4 <=> 46 IN 4 (X4)20 Input 5 <=> 21 IN 5 (X4)21 Input 6 <=> 45 IN 6 (X4)22 Input 7 <=> 20 IN 7 (X4)2324252627 0V for Pin 29 - 32 <=> 49 Power supply 0V28 12 / 24 V for Pin 29 - 32 <=> 2 Power supply 24V29 Output 4 <=> 5 OUT 4 (X2)30 Output 5 <=> 30 OUT 5 (X2)31 Output 6 <=> 6 OUT 6 (X2)32 Output 7 <=> 31 OUT 7 (X2)333435 Output 12 <=> 10 OUT 12 (X2)36 Output 13 <=> 35 OUT 13 (X2)37 Output 14 <=> 11 OUT 14 (X2)38 Output 15 <=> 36 OUT 15 (X2)39 COM1 for Pin 40 - 47 <=> 50 Power supply 0V40 Input 8 <=> 43 IN 8 (X4)41 Input 9 <=> 18 IN 9 (X4)42 Input 10 <=> 42 IN 10 (X4)43 Input 11 <=> 17 IN 11 (X4)44 Input 12 <=> 41 IN 12 (X4)45 Input 13 <=> 16 IN 13 (X4)46 Input 14 <=> 40 IN 14 (X4)47 Input 15 <=> 15 IN 15 (X4)484950

Drive - Unit


IN 0 IN 2 IN 3 IN 4 IN 6 IN 7

Conveyor system AS-i

01: Assembly 10: Rejection 11: bei Bus: Part on pallet load.

IN 8 IN 10 IN 11 IN 12 IN 14 IN 15 OUT 0 OUT 2 OUT 3 OUT 4 OUT 6 OUT 7 OUT 8 OUT 10 OUT 11 OUT 12 OUT 14 OUT 15

I/O-Terminal Magazine

I/O-Terminal Robot

Controlpanel

RIA-Box

PART AV

Foll.Stat Fok

START

XMA XMB XMC

X M D

STOP RESET

B2 (Orient.)

B1 (Color)

IN 2 IN 3

OUT 2 OUT 3

IN 0 IN 1

OUT 0 OUT 1

SYSLINK (AS-i)

AS-I Addr: AS-I Addr:




Station ok Order run (busy)

ERR CODE #0 ERR CODE #1

PART AV Following Station ok

Using MPS, change the bridge

Wiring of the RIA Box

2.2 Connection RIA – Box

XMA, XMB, XMC, XMD


Drive Unit

After switch on the drive unit, please make sure the robot arm is near the position 99 already, because the robot maybe cannot move to position 99 from any other

position (collision with the magazines).

If the robot arm is not near the position 99, please move the arm using the Teach-Box to P99. To do so, please switch the key-switch of the drive unit to the

position TEACH, then switch the key switch of the Teach-box to position ENABLE.

By pressing the dead-man-switch permanently and pressing the Step/Move button, you can move the robot-axis using the J1-J6-buttons near to the position 99.

After this, please switch the key-switches back to the positions:

AUTO(OP) on the drive unit and DISABLE on the Teach-box.

Choose the program NO. 1 on the drive unit by pressing the button CHNG/DISP as

long as P.0001 will appear on the screen

Now please activate the servo motors by pressing the SVO ON button-please wait

until the LED of this button is on.

Now please press the START button-LED is on – the program is now active.

You can start the program also from the Software. Please switch the key-switch of

the drive unit to AUTO (EXT.) and the key-switch of the Teach Panel to DISABLE.

Now start up the Software COSIMIR Industrial or COSIROB. Click on Execution – Connection Robot to connect the robot with the computer.

Click on Extras – Program Directories and you will be able to see the actual directory

of the drive unit. Choose Program 1 and start it.

Reset conditions

Press the RESET button on the Control Panel to move the robot to it´s starting

position P99. After reaching P99, the LED of the Reset-button is on.

Process Start

To start the process, press the START button once, the Reset-LED is off and the Start-

LED is on

Missing springs will be shown by LED Q1,

missing covers by LED Q2. If piston rods are missing (black or metal), the LED´s Q1 and Q2 are on.

Please refill the corresponding material and press START button once to continue with the process.

3. Commissioning


If the robot is not able to detect the orientation of the base, it will be rejected. If the

robot is not able to detect the orientation of the cover, it will be also rejected and the LED´s Q1 and Q2 are flashing alternating, this means also to remove the base by

hand – the process will be interrupted. By pressing START button once, the LED´s

stop flashing and the robot continue with the assembly process.

If there is a vision system available within the FMS to detect good and bad parts, the

robot will reject the bad parts out of the production process. The maximum amount of rejected workpieces is controlled via a counter inside the

robot-program. If the maximum amount of bad workpieces is exceeded, the LED´s

Q1 and Q2 are flasing alternating and the process will be interrupted. Empty the rejection magazine and quit by pressing the START button again. The process

continue.

A running process can be interrupted at any time by pressing the STOP button.

The START LIGHT is flashing. After pressing the START button again, the process

continue.

Changing Program

If a changed or new program should be downloaded to the drive unit, please step by

step execute following instructions. Be advised that different programs in the drive

unit independent from each other could lead to interactions and perhaps to problems.

1. Establish a connection between the robot drive unit and the computer by activating "Execute → Init Connection".

2. Acticate the window of the written program and "Execute → Download

PCàRobot" to open download window. See to it that the shown amount of program lines is higher than the actual

amount of program lines. The best way not to loose track of which program is

in the drive unit and which should be downloaded, please insert below "Program Name" the window name .

3. "→ Download".

4. If there is a program listing for the downloaded program it also can be downloaded by the command " Execute → Download PC→Roboter".

Be again advised to use a suitable window name.

5. Programs also can be started by the command "Execute → Start Program". 6. Test program and stop it with "Execute → Start Program"

During a active connection it is possible to see the program contens of the drive unit if you execute the command "Extra → Program Directory".


4.1 Program FMS_50

All positions have been defined by using a red workpiece.

P1 Retrieve and return position on the pallet with RED

workpiece (outer gripper jaws)

P2 Workpiece mounting, teach with cone gauge in inner

gripper jaws. Rotate outer gripper jaws into direction of robot. The gripper jaws should be parallel to the X-

axis of the robot.

P3 Identify workpiece if black or not black with optical

sensor in gripper jaws

P4 Gripping position at magazin for springs

P5 Position at piston pallet, teach with cone gauge in inner gripper jaws

P6 Release position if there is no detection during rotation of workpieces and covers

P9 Gripping position for covers

P99 Normal postion

4. Robot positions


Position P1 - Retrieve and return position on the pallet with RED workpiece

(outer gripper jaws)

Position P1


Position P99 – Normal position

Position P6 - Release position if there is no detection during rotation of workpieces

and covers


Position P2 - Workpiece mounting, teach with cone gauge in inner gripper jaws.

Rotate outer gripper jaws into direction of robot. The gripper jaws should be parallel to the X-axis of the robot.

Position P2

© Festo Didactic GmbH & Co.

Position P3 - Identify workpiece if black or not black with optical sensor in right

gripper jaw

Position P3


Position P4 - Gripping position at magazine for springs

Position P9 - Gripping position for covers


Position P5 - Position at piston pallet, teach with cone gauge in inner gripper jaws

Position P5


Inputs

Address Parameter Function

0 Stopp all

slots

1 Optical sensor in gripper for black/no black workpiece

2 Optical sensor for measuring orientation

3 Control panel – START button

4 Control panel – STOP button

5 Control panel – RESET button

6 Nc

7 Communication with Conveyor – Input for start assembly

8 Spring magazine – slider retracted

9 Spring magazine – slider extended

10 Cover magazine – slider extended

11 Cover magazine – slider retracted

12 Spring in mounting

13 No cover at gripping position

14 No cover in magazine

15 IP following station occupied

Outputs

Address Parameter Function

0 Control panel – START lamp

1 Control panel – RESET lamp

2 Control panel – Q1lamp

3 Control panel – Q2 lamp

4 Errror Code Bit 0 for feedback to Conveyor

5 Error Code Bit 1 for feedback to Conveyor

6 Robot Assembly Station "busy" signal

7 Robot Assembly Station "ready" signal

8 Distribute spring

9 Retract slider of cover magazine

10 NC

11 NC

12 NC

13 NC

14 NC

15 NC

5. Robot Inputs and Outputs


5.2 Handshake

10

10

10

10

10

10

M_out (7) Robot ready

M_in (6)Assembly start

M_in (7) bad part

M_out(6) Robot busy

t=500 msM_0ut(4) Error Bit 0

M_out (4) Errror Bit 1

t=500 ms

18 © Festo Didactic GmbH & Co. • MPS

6.1 Program structure

The robot program is written in a sequence. There is only one program for

downloading to the drive unit.

Peripheral units like valves or sensors are controlled by the drive unit. In a main program loop subroutines are executed :

- retrieve workpiece

- insert piston (corresponding to workpiece) - insert spring

- assemble cover

Simultaneous a interrupt function monitors the STOP button of the control panel. If

activated the program will be paused in any position.

Following input signals are the communication between conveyor and

robot&assembly:

robot output bit No.7 = Assembly ready robot input bit No. 6 = Start assembly

robot input bit No. 7 = bad part → sort out

With the opitcal sensor of the gripper the value for the Z-height between "black"

and "not-black" is evaluated. Therefore all existing positions in the program are

calculated with this parameter. There is only one variable position for all workpieces "black" or "not-black" "black assembled" and "not-black assembled".

After finishing the assembly the PLC will get a return code for: - executed assembly

- put back on pallet

- bad part Than the main loop will start from the beginning.

Error Handling:

There is no error handling if a error of the conveyor PLC occurs.

A error of the drive unit (collision, emergency) will stop the program. Robot has to be

moved with teach box out of the collision area and the program restarted.

6. FMS50 Robot-Program

fms50 robot assembly gb a001

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